Battery Thermal Barrier Using Composite Insulation Paste
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Solution Overview
Problem
Lithium ion batteries in automotive applications face the risk of thermal runaway above 80-100 °C, leading to uncontrolled decomposition, heat increase, and potential cell rupture, posing safety concerns in vehicles.
Innovation Solution
A battery protection composite construction comprising a mesh or fabric made from metals, carbon fiber, or ceramic fiber, combined with an inorganic insulation layer and optionally a metal layer, designed to mitigate thermal runaway by dissipating heat and mechanical stress, and providing structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal insulation materials are used to prevent thermal runaway, then thermal resistance is improved, but mechanical strength and structural stability deteriorate
Solution Approach 1:
The patent employs a composite construction consisting of an inorganic insulation layer combined with a mesh or fabric reinforcement layer. The mesh comprises metal wires, carbon fibers, or ceramic fibers that provide mechanical strength while the inorganic insulation layer provides thermal resistance. This composite structure resolves the contradiction by integrating both thermal insulation and mechanical reinforcement functions into a single protective element.
2Temperature
If thick insulation layers are applied to cells, then thermal protection is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the thermal insulation function and mechanical reinforcement function into a single integrated protective layer. The mesh structure is embedded within the inorganic insulation layer, creating a unified component that provides both thermal protection and structural integrity. This combination simplifies the overall construction compared to applying separate thick insulation layers and separate reinforcement structures.
Solution Approach 2:
The protective construction uses a thin film or layer approach where the mesh and insulation are combined in a relatively thin composite structure. This thin-film design provides effective thermal protection without requiring thick insulation layers, thereby reducing device complexity and maintaining a compact battery assembly.
3Strength
If mesh materials are used for structural support, then mechanical strength is improved, but thermal insulation performance deteriorates
Solution Approach 1:
The patent creates a composite where the mesh structure and insulation layer work synergistically. The mesh provides the structural framework and mechanical strength, while the inorganic insulation layer surrounding the mesh provides the thermal insulation. The combination achieves both structural stability and thermal protection, with each component compensating for the other's limitations.
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 composite construction effectively prevents or slows down thermal runaway events by dissipating heat and mechanical stress, ensuring the safety of surrounding cells and passengers by withstanding high temperatures and pressure increases.
Implementation Method 1
at least one inorganic insulation layer
Implementation Method 2
at least one mesh or fabric comprising at least one material selected from metals, carbon fiber, and ceramic fiber
Data Source
AI summary
In one aspect of the present disclosure, there is provided a battery protection composite construction, comprising (a) At least one mesh or fabric comprising at least one material selected from metals, carbon fiber, and ceramic fiber, and any combinations and mixtures thereof; and (b) At least one inorganic insulation layer; (c) Optionally, at least one metal layer; (d) Optionally, at least one layer distinct from (a), (b) and (c).