Phase-Change Insulation Sheet for Battery Thermal Runaway Barriers
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Solution Overview
Problem
Heat propagation between adjacent rechargeable battery cells poses a safety hazard, particularly during thermal runaway, necessitating a solution to reduce or prevent heat transfer and enhance safety.
Innovation Solution
An insulation sheet comprising multiple layers, including a first layer for structural support, a second layer for insulation, and optionally a third layer with a phase change material for improved thermal conductivity and fire resistance, is interposed between battery cells to mitigate heat propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple battery cells are disposed adjacent to each other to increase capacity, then energy density and productivity are improved, but heat propagation between cells occurs worsening safety and reliability
Solution Approach 1:
An insulation sheet is introduced as an intermediary component between adjacent battery cells. The sheet includes a base layer providing structural support and insulation, plus a phase change material layer that actively absorbs heat through phase transition. This intermediary structure physically separates cells and thermally isolates them, preventing heat propagation while maintaining compact arrangement for high capacity.
Solution Approach 2:
The insulation sheet incorporates a phase change material layer that utilizes phase transition (solid-liquid or liquid-gas) to absorb excessive heat generated during battery operation or thermal runaway events. The phase change material absorbs large amounts of heat energy during its phase transition, effectively suppressing heat propagation to adjacent cells and enhancing safety without compromising battery density.
2Reliability
If insulation material is added between battery cells to prevent heat propagation, then safety is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The insulation sheet employs a composite structure combining a base layer (providing structural integrity and basic insulation) with a phase change material layer (providing active heat absorption). This composite design achieves superior thermal insulation performance in a single integrated component, avoiding the need for multiple separate insulation layers or complex assembly procedures, thus limiting the increase in manufacturing complexity.
3Reliability
If phase change material layer is added to improve thermal conductivity and fire resistance, then fire resistance and thermal management are improved, but manufacturing precision and coating uniformity become more difficult
Solution Approach 1:
The patent specifies optimized parameter ranges for the phase change material layer, including thickness (1-10 μm) and content (1-20 wt%), to achieve effective fire resistance and thermal management. By defining specific parameter windows, the invention balances performance requirements with manufacturing feasibility, ensuring that the coating can be applied uniformly without requiring extreme manufacturing precision.
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 insulation sheet effectively reduces heat transfer between cells, enhances safety by preventing thermal runaway, and improves impact resistance and fire resistance, while maintaining structural integrity.
Implementation Method 1
one or more third layers which are each formed on one surface of the second layer and include a phase change material
Data Source
AI summary
The present disclosure relates to an insulation sheet and a battery module including the insulation sheet. The insulation sheet includes one or more first layers, one or more second layers which are each formed on one of the one or more first layers and include an insulating material, and one or more third layers which are each formed on one surface of the one or more second layers and include a phase change material.