Battery Cell Refractory Layer and Spacer for Thermal Runaway Blocking
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Solution Overview
Problem
Existing battery systems fail to effectively prevent the deformation of the battery container due to cell swelling and the propagation of thermal runaway between cells, particularly in lithium-ion batteries, as they either compromise thermal insulation or increase battery length.
Innovation Solution
A battery design incorporating a refractory material layer in contact with the entire face of the cell, combined with a rigid spacer outside the central region to maintain spacing and prevent compression, ensuring thermal insulation and preventing thermal runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid spacer is placed between cells to maintain spacing, then cell spacing is maintained and box deformation is prevented, but thermal insulation between cells is reduced
Solution Approach 1:
The spacer is constructed as a composite structure combining a rigid outer framework (providing mechanical support and spacing) with a refractory material core (providing thermal insulation). This composite design allows the spacer to simultaneously maintain cell spacing and block heat propagation between cells.
Solution Approach 2:
The spacer applies different material properties to different regions: the outer framework uses rigid material for structural support, while the central region uses refractory material for thermal insulation. This local differentiation of material properties allows the single spacer component to fulfill both mechanical and thermal functions.
2Object-affected harmful factors
If a layer of heat-resistant material is placed between cells to prevent thermal runaway, then thermal insulation is improved, but the material gets crushed under cell swelling and insulation effectiveness decreases
Solution Approach 1:
The heat-resistant material is embedded within a rigid spacer structure, creating a composite where the rigid framework provides compression resistance while the heat-resistant material maintains thermal insulation. The rigid structure prevents the heat-resistant material from being crushed under cell swelling forces.
Solution Approach 2:
The rigid spacer structure is pre-configured to withstand compression forces from cell swelling before thermal runaway occurs. This pre-engineered structural support ensures that the heat-resistant material maintains its thickness and insulation properties even under compression, preventing insulation failure.
3Object-affected harmful factors
If air gaps are introduced between cells for thermal insulation, then heat propagation is reduced, but battery length increases
Solution Approach 1:
The refractory material is configured as a thin film or layer within the spacer structure, providing effective thermal insulation without requiring large thickness. This thin-layer approach blocks heat propagation while minimizing the increase in battery length.
Solution Approach 2:
The composite spacer structure integrates the refractory material layer within a compact rigid framework, achieving thermal insulation in a space-efficient manner. The rigid framework provides structural support while the embedded refractory layer provides thermal blocking, together preventing heat propagation without significantly increasing battery dimensions.
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 solution maintains battery length constancy while effectively preventing thermal runaway by using a refractory material layer and a rigid spacer, ensuring thermal insulation and maintaining cell spacing.
Implementation Method 1
a first layer of a refractory material able to withstand a temperature up to 1200° C., disposed in contact with the entirety of a first face which is one of the faces of largest area of one of the electrochemical cells
Implementation Method 2
a rigid spacer having a hardness greater than or equal to 90 Shore A according to standard ASTM D 2240-15 (2021), placed between said first layer and the second electrochemical cell
Data Source
AI summary
A battery including at least two electrochemical cells of parallelepiped format; a first layer of a refractory material able to withstand a temperature up to 1200° C. placed in contact with the entirety of a first face which is one of the faces of largest area of one of the electrochemical cells, the first layer including a central region having as its center the center of the first layer and having an area representing 30 to 60% of the area of said first face; and a rigid spacer having a hardness greater than or equal to 90 Shore A according to standard ASTM D 2240-15, placed between said first layer and the second electrochemical cell (2-2), the rigid spacer being located outside of the central region of said first layer.