Battery Cell Thermal Runaway Barrier with Nonwoven Silica Layer
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Solution Overview
Problem
Lithium ion batteries in electric vehicles are prone to thermal runaway events, leading to overheating and destruction of battery cells, which existing technologies have not effectively prevented or slowed down.
Innovation Solution
A thermal runaway barrier comprising a nonwoven fibrous thermal insulation layer with inorganic fibers and thermally insulative fumed silica particles, optionally encapsulated with organic and inorganic layers, is placed between battery cells to absorb heat and prevent propagation of thermal events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If battery cells are disposed compactly to save space, then space utilization is improved, but thermal runaway propagation risk increases
Solution Approach 1:
The patent introduces thermal runaway barriers that segment the battery pack into isolated zones. These barriers physically divide the compact battery cell arrangement into separate thermal management zones, preventing heat and flame propagation between adjacent cells while maintaining the compact overall structure. The barrier layers create thermal isolation segments within the densely packed battery configuration.
Solution Approach 2:
The thermal runaway barrier acts as an intermediary material placed between adjacent battery cells. This intermediate layer serves as a thermal buffer that absorbs and reflects heat, blocking thermal runaway propagation from one cell to another while allowing the battery cells to remain in close proximity for space efficiency.
2Reliability
If thermal runaway barriers are added between battery cells, then thermal runaway propagation is slowed down, but device complexity increases
Solution Approach 1:
The thermal runaway barrier is constructed as a thin film or flexible layer that can be easily integrated between battery cells. This thin-film approach provides effective thermal protection without adding significant structural complexity or volume to the battery assembly. The flexible nature of the barrier allows it to conform to the battery cell geometry and be installed with minimal modification to the existing battery pack structure.
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 significantly slows down thermal runaway events, allowing for safer battery operation by maintaining adjacent battery cells below critical temperature thresholds and preventing widespread overheating.
Implementation Method 1
a layer of a nonwoven fibrous thermal insulation comprising a fiber matrix of inorganic fibers
Implementation Method 2
thermally insulative inorganic particles comprising fumed silica dispersed within the fiber matrix
Data Source
AI summary
A thermal runaway barrier for at least significantly slowing down a thermal runaway event within a battery assembly. The thermal runaway barrier includes a layer of a nonwoven fibrous thermal insulation comprising a fiber matrix of inorganic fibers, thermally insulative inorganic particles of fumed silica dispersed within the fiber matrix, and a binder dispersed within the fiber matrix so as to hold together the fiber matrix. An optional organic encapsulation layer may also be used to encapsulate the nonwoven fibrous thermal insulation.