Battery Thermal Barrier Composition for Cell-to-Cell Heat Isolation
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Solution Overview
Problem
High voltage batteries in electrochemical cells face issues with excessive heat transfer leading to overheating, which can disrupt the electrochemical components and system, and existing cooling mechanisms may inadvertently transfer heat between cells.
Innovation Solution
A thermal barrier layer composed of a polymer network with inorganic and organic portions, including milled fiber, Aerogel, hollow microspheres, and mineral filler, providing thermal stability up to 600°C and thermal conductivity of no more than 0.3 W·m−1·K−1, is applied adjacent to the electrochemical cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling plates are used to reduce overheating, then thermal management of individual cells is improved, but heat transfer between cells is increased
Solution Approach 1:
A thermal barrier layer is introduced as an intermediary substance between adjacent electrochemical cells. This layer has low thermal conductivity to block heat transfer from one cell to another, while allowing cooling plates to continue functioning for individual cell thermal management. The barrier layer mediates between the need for effective cooling and the need to prevent harmful heat transfer between cells.
Solution Approach 2:
The thermal barrier layer is applied locally at specific interfaces between cells rather than uniformly throughout the entire battery system. This targeted approach provides thermal isolation where needed (at cell boundaries) while maintaining effective thermal contact between cells and cooling plates, allowing local optimization of thermal management without compromising overall system performance.
2Object-affected harmful factors
If thermal barrier layer with low thermal conductivity is applied, then heat transfer between cells is reduced, but system complexity increases
Solution Approach 1:
The thermal barrier layer utilizes porous or cellular material structures that provide effective thermal isolation through trapped air or vacuum pockets. These porous structures achieve low thermal conductivity with relatively simple material composition and application processes, reducing system complexity compared to solid dense barrier materials while maintaining effective thermal blocking between cells.
3Stability of the object's composition
If high thermal stability material is used for thermal barrier, then thermal stability is improved, but manufacturing difficulty increases
Solution Approach 1:
The thermal barrier layer employs composite material formulations combining organic and inorganic components, such as polymer matrices with ceramic fillers or porous structures. These composites achieve high thermal stability (withstanding temperatures up to 600°C or higher) while maintaining processability and compatibility with standard manufacturing techniques, reducing the difficulty of integration into existing battery production lines.
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 thermal barrier layer effectively insulates electrochemical cells, preventing excessive heat transfer and maintaining system integrity by reducing thermal conductivity and enhancing thermal stability.
Implementation Method 1
The thermal barrier layer may have a thermal stability of at least 600° C. and a thermal conductivity of no more than 0.3 W·m−1·K−1
Data Source
AI summary
An electrochemical system having a thermal barrier layer is provided. The thermal barrier layer includes a polymer network having an inorganic portion and an organic portion such as silicone or a polysiloxane polymer network. The polymer network may further include filler component dispersed therein such as oxidized polyacrylonitrile milled fiber, Aerogel, hollow glass microspheres, and mica.