Battery Module Silicone Curing for Thermal Runaway Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermal runaway mitigation solutions for electric vehicle batteries, such as expanding polyurethane and epoxies, are limited by additives that may not effectively participate in or can be detrimental to the mitigation process, and require physical enclosures for application, which can be restrictive and inefficient.
Innovation Solution
The use of silicone-based polymers, which are injected into a mold holding battery cells and cured under controlled temperature and additive conditions, allowing for precise control of the curing reaction rate and viscosity, enabling effective thermal runaway protection without the need for physical expansion or sealed enclosures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expanding polyurethane or epoxy is used as thermal runaway mitigation solution, then physical space between battery cells is filled and thermal chain reaction is limited, but additives in the expanding mechanism may be detrimental to runaway mitigation and require physical enclosure during application
Solution Approach 1:
The patent removes the expanding mechanism and its additives from the thermal runaway mitigation solution, using only silicone polymer without expansion capabilities. This extraction eliminates the harmful additives while maintaining the protective function, and removes the requirement for physical enclosures during application.
Solution Approach 2:
The patent changes the fundamental parameter of the solution from expanding (volume increase) to non-expanding (volume stable). By using silicone polymer that maintains its volume throughout curing, the patent eliminates the need for enclosures and harmful expanding additives, while still providing effective thermal protection.
2Reliability
If traditional expanding solutions are used, then thermal protection is provided, but physical enclosure is required during application which limits manufacturing flexibility
Solution Approach 1:
The patent extracts and removes the expanding mechanism that necessitates physical enclosures. By using silicone polymer without expansion capabilities, the solution maintains thermal protection while eliminating the requirement for complex enclosed application processes, thereby improving manufacturing ease and flexibility.
3Productivity
If silicone polymer is injected into mold with controlled curing, then curing time is reduced and production efficiency is improved, but precise control of temperature and additives is required
Solution Approach 1:
The patent incorporates curing catalysts and temperature control mechanisms into the injection system itself, allowing curing to begin immediately upon injection and continue during the process. This preliminary integration of curing functionality into the injection apparatus eliminates the need for separate, complex curing equipment while maintaining fast curing times.
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
This approach significantly reduces curing time, improves production efficiency, and enhances the quality of the final product by allowing for precise control of the silicone curing process, reducing capital investment and operational costs while providing comprehensive thermal protection for electric vehicle batteries.
Implementation Method 1
whose curing reactions are triggered when the participating reactants come into contact with each other under the right temperature and pressure conditions
Implementation Method 2
the temperature of the one of the mold as a whole or the specific portions of the mold is controlled until curing of the injected silicone mixture is complete
Data Source
AI summary
In using silicone to control thermal runaway in a battery module for an electric vehicle, a mold is provided to hold a plurality of energy storage elements with spaces in between adjacent ones thereof. Substantially uncured silicone polymer mixture is injected into the mold to fill the spaces. During fill of the mold with the injected silicone polymer mixture, variation is introduced of one or more of: a ratio of constituents of the silicone polymer mixture being injected; at least one of a presence or absence of additive(s) in the injected silicone polymer mixture, type(s) of the additive(s) in the injected silicone polymer mixture, or concentrations of the additive(s) in the injected silicone polymer mixture; or mold temperature. Upon completion of the fill of the mold with the injected silicone polymer mixture, curing of the injected silicone polymer mixture is completed. Precise, fast cure of the silicone is achieved.