Multilayer Cell Spacer Barrier for Thermal Runaway Gas Containment

The patent applies different material properties to different regions of the thermal barrier: the core layer uses highly porous materials with low thermal conductivity for maximum insulation with minimal thickness, while the skin layer uses dense materials for gas containment. This localized differentiation of material quality achieves superior thermal barrier performance without requiring uniform thickness throughout, thereby reducing overall device complexity.

The patent utilizes porous materials (such as aerogels, foam structures, or fibrous materials) in the core layer that provide exceptional thermal insulation with very low density and minimal thickness. The porous structure creates tortuous heat paths that significantly reduce thermal conductivity, enabling effective heat dissipation without increasing material thickness or device complexity.

The patent employs a dynamic structural design where the core porous layer can compress and deform elastically to accommodate battery cell expansion during charging cycles, while the dense skin layer maintains its structural integrity for thermal runaway protection. This dynamic adaptability allows the thermal barrier to adjust to changing cell dimensions without compromising its protective function.

The patent uses a flexible porous core structure that can deform and adapt to cell volume changes during charging and discharging. The porous network structure allows for compression and expansion while maintaining thermal insulation properties, providing both thermal runaway protection and adaptability to cell dimensional changes.

The patent utilizes highly porous insulation materials with extremely low density (such as aerogels or fine-cell foams) that provide superior thermal barrier performance per unit mass and volume. The porous structure contains大量 air pockets that inhibit heat transfer while adding minimal weight and occupying minimal space, thereby enhancing safety without significantly reducing energy density.

The patent segments the thermal barrier into two functional layers with distinct thicknesses and material properties: a thin dense skin layer for gas containment and a thicker porous core layer for thermal insulation. This segmentation optimizes the weight and volume distribution, ensuring that the majority of the material volume is dedicated to low-density insulation that provides maximum thermal protection per unit mass, thereby preserving energy density while enhancing safety.