Battery Insulation Shield With Segmented Bands for Thermal Propagation
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Solution Overview
Problem
Traction battery packs in electrified vehicles face challenges with thermal propagation and pressure increases due to overcharge, overdischarge, or short circuit events, which can lead to battery cell rupture and heat generation, necessitating effective insulation to prevent thermal events from spreading across the array.
Innovation Solution
An insulation shield with a wrapping structure comprising multiple bands of wire strips, forming discrete closed loops around a layered structure including aerogel and metal layers, positioned between battery cells or arrays to maintain structural integrity and manage thermal energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealed wrapping configurations are used, then thermal insulation is provided, but cost and manufacturing complexity increase
Solution Approach 1:
The wrapping structure is segmented into multiple discrete bands instead of a continuous sealed wrap. Each band is positioned at specific locations around the shield body, creating a modular structure that reduces manufacturing complexity while maintaining thermal insulation effectiveness. The bands are spaced apart to allow for thermal management while providing structural support.
Solution Approach 2:
The wrapping structure applies insulation locally at critical thermal pathways rather than providing uniform sealed wrapping throughout. The bands are strategically positioned at locations where thermal propagation is most likely to occur, such as at the edges and corners of the shield body, providing targeted thermal protection where it is most needed while reducing overall material usage and complexity.
2Reliability
If sealed wrapping configurations are used, then thermal propagation is restricted, but manufacturing cost increases
Solution Approach 1:
The continuous sealed wrapping is segmented into discrete bands that can be manufactured independently and assembled more easily. This segmentation allows for simpler manufacturing processes, reduced material costs, and easier assembly while still providing effective thermal propagation restriction at the most critical locations.
Solution Approach 2:
The wrapping structure uses simpler, less expensive band materials and construction methods compared to traditional sealed wrapping. The discrete bands can be made from cost-effective materials and assembled using simpler processes, reducing overall manufacturing cost while maintaining adequate thermal protection performance.
3Duration of action of stationary object
If multiple bands are used in the wrapping structure, then thermal propagation time increases, but structural complexity increases
Solution Approach 1:
The wrapping structure is divided into multiple discrete bands positioned at strategic locations around the shield body. This segmentation creates multiple thermal barriers that collectively increase thermal propagation time, as heat must navigate around and through each band rather than spreading continuously. The segmented approach achieves thermal management goals while keeping each individual band simple in design.
Solution Approach 2:
The multiple bands are arranged in different spatial dimensions and orientations around the shield body, creating a three-dimensional thermal barrier network. This multi-dimensional arrangement effectively increases thermal propagation time by forcing heat to travel through complex paths, while the modular band structure keeps individual components simple and manageable.
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 wrapping structure effectively reduces maximum skin temperature by 40% and increases thermal propagation time, while being more cost-effective and efficient than traditional sealed wrapping configurations, thereby enhancing safety and performance.
Implementation Method 1
The plurality of layers comprise at least a first aerogel layer and a second aerogel layer with a first metal layer between the first and second aerogel layers
Implementation Method 2
a wrapping structure comprising a plurality of bands, wherein at least one band of the plurality of bands extends around the shield body in a longitudinal direction
Data Source
AI summary
An insulation shield for a battery pack includes a shield body that is configured to be positioned between adjacent battery components, and a wrapping structure comprising a plurality of bands. At least one band of the plurality of bands extends around the shield body in a longitudinal direction and at least one other band of the plurality of bands extends around the shield body in a lateral direction.