Electrochemical Cell Assembly With Intumescent Thermal Isolation
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Solution Overview
Problem
Existing solutions for preventing thermal runaway in electrochemical cells require expensive high-thermal-resistance materials and facilitate heat transfer due to the use of thermally conductive mechanical assembly systems, increasing battery costs and risk of propagation.
Innovation Solution
Incorporation of intumescent materials that swell upon heat exposure to prevent thermal runaway by causing the casing to rupture, eliminating the need for costly thermal insulation and reducing heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-thermal-resistance insulating layers are used to prevent thermal runaway propagation, then thermal insulation effectiveness is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the thermal insulation mechanism from passive high-thermal-resistance materials to active intumescent materials that transform their properties when exposed to heat. The insulating layer transitions from a thin, low-cost state to a thick, high-insulation state upon thermal activation, resolving the contradiction between insulation effectiveness and manufacturing cost
Solution Approach 2:
The intumescent insulating layer undergoes a phase transition when exposed to heat, expanding from a compact state to a voluminous foam structure. This phase change enables the material to achieve high thermal insulation properties temporarily when needed, without requiring expensive permanent insulation materials
2Strength
If thermally conductive mechanical assembly systems are used for battery assembly, then mechanical strength and assembly ease are improved, but heat transfer between cells increases
Solution Approach 1:
The patent introduces an intumescent insulating layer as an intermediary between electrochemical cells and the mechanical assembly system. This layer acts as a thermal barrier that prevents heat transfer while allowing the mechanical assembly system to maintain its thermally conductive, high-strength properties for efficient heat dissipation during normal operation
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
Effectively prevents thermal runaway propagation while reducing costs by using intumescent materials that swell and rupture the casing to isolate cells, enhancing thermal insulation and mechanical stability.
Implementation Method 1
the intumescent means 28 are capable of swelling when subjected to a temperature greater than or equal to a swelling temperature
Implementation Method 2
the frangible part 40 is configured to break under the effect of the swelling of the intumescent means 28
Data Source
Figure 1
Figure 2
AI summary
The invention relates to an assembly (12) comprising: - a stack comprising a plurality of electrochemical cells (22) arranged along a longitudinal direction (X) and a plurality of insulating layers (24), and - a housing (26) defining a cavity in which the stack (20) is received. The stack (20) further comprises intumescent means (28) arranged along the longitudinal direction (X) between two adjacent electrochemical cells (22), the intumescent means (28) being capable of swelling when subjected to a temperature above a swelling temperature. The housing (26) comprises at least one frangible portion (40) configured to rupture under the effect of the swelling of the intumescent means (28).