Crushable Insert Layer for Battery Pressure Buildup Control
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Solution Overview
Problem
Rechargeable batteries, such as lithium-ion batteries, experience uncontrolled buildup of internal pressure during recharging cycles due to expansion, leading to potential damage and thermal runaway when confined in rigid fixtures.
Innovation Solution
Incorporating a crushable insert layer, such as metal honeycomb or porous metal foam, within the battery fixture to limit internal pressure buildup by accommodating the battery's expansion through permanent deformation, thereby controlling pressure within a safe range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid battery fixture is used to confine the battery cell, then structural support and containment are improved, but internal battery pressure buildup increases uncontrollably during recharging cycles
Solution Approach 1:
The battery fixture transitions from a completely rigid structure to one with controlled compliance through the crushable insert layer. This layer has a specific crushing strength parameter that changes from rigid support to controlled deformation at a threshold pressure, allowing the system to adapt its mechanical properties based on the operational state
Solution Approach 2:
The crushable insert layer acts as an intermediary element between the rigid battery fixture and the battery cell. It mediates the interaction by providing structural support when needed while absorbing excess pressure through controlled crushing, preventing direct transmission of harmful forces to the battery cell
2Volume of moving object
If the battery cell is confined in a rigid fixture, then spatial containment is improved, but battery expansion during recharging causes uncontrolled pressure buildup
Solution Approach 1:
The battery fixture incorporates a dynamic element (the crushable insert layer) that can change its volume and density during operation. The layer transitions from a low-density crushable structure to a densified state as it absorbs expansion forces, allowing the system to accommodate volume changes dynamically while maintaining containment
Solution Approach 2:
The crushable insert layer is strategically positioned in specific locations within the battery fixture where pressure buildup is most critical. This localized placement allows the fixture to maintain rigidity in non-critical areas while providing controlled compliance where needed to manage pressure
3Duration of action of stationary object
If multiple recharging cycles are performed, then battery usability is improved, but internal pressure continuously increases leading to damage and thermal runaway
Solution Approach 1:
The crushable insert layer is pre-positioned within the battery fixture to provide cushioning protection before pressure buildup becomes dangerous. This layer acts as a safety mechanism that is already in place to absorb and dissipate expansion forces during normal recharging cycles, preventing catastrophic failures
Solution Approach 2:
The expansion forces that would normally be harmful and lead to pressure buildup are converted into a beneficial effect by the crushable insert layer. The layer's controlled crushing absorbs the expansion energy, transforming what would be a damaging force into a protective mechanism that extends battery life and maintains safety
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The crushable insert layer effectively limits internal battery pressure to prevent damage and thermal runaway by allowing the battery to expand without exceeding critical thresholds, ensuring safe operation during multiple recharging cycles.
Implementation Method 1
The crushable insert layer and the rigid battery fixture are cooperatively configured to limit internal battery pressure buildup inside of the battery cell during recharging cycles
Data Source
AI summary
Excessive expansion of rechargeable batteries during recharging is a significant concern since the uncontrolled buildup of high internal battery pressures from expansion inside a confined space can lead to separator membrane failure and/or thermal runaway of a battery cell. A crushable foam or honeycomb insert layer is placed inside of a rigid battery fixture to automatically limit the progressive buildup of internal battery pressure due to charging-induced expansion of the battery cell during recharging. The crushable insert layer is included as part of the rigid battery fixture. Aluminum honeycomb cores and porous aluminum metal foam materials have a significant amount of crushability over a very wide range of compressive strains. Alternatively, a porous metal foam or metal honeycomb material may be infused with a liquid polymer (e.g., silicone, rubber, EDPM, or polyurethane) to enhance the mechanical properties of the polymer-infused metal foam or honeycomb metal/polymer composite material.