Ceramifying Silicone Coating for Battery Module Thermal Insulation
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Solution Overview
Problem
Existing thermal insulation materials for lithium ion batteries in electric vehicles are either too expensive, difficult to apply, or lack sufficient thermal stability during high-temperature events, posing a risk of fire and potential damage to surrounding components.
Innovation Solution
A sprayable, thixotropic, crosslinkable organosilicon composition containing greater than 50% aluminum trihydrate as a fire retardant and ceramifying filler, which provides high thermal insulation and forms an insulative solid during high-energy events, reducing heat transfer to the exterior of the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional insulation materials (foam plastics, air gaps, insulating plates) are used, then thermal insulation is provided, but thermal contact between battery cells is reduced leading to insufficient heat generation during cold weather
Solution Approach 1:
The thermal management system applies different thermal characteristics to different regions: insulation material is placed at specific locations where thermal isolation is needed, while thermal conductive material is applied at contact surfaces where heat transfer is required. This local differentiation allows simultaneous thermal insulation and heat generation.
Solution Approach 2:
A thermal management layer acts as an intermediary between the battery cell and insulation material. This layer includes both insulating and thermally conductive components that mediate between the conflicting requirements of thermal isolation and thermal contact, enabling both functions to coexist.
2Loss of energy
If insulation material is placed between battery cells, then thermal isolation is achieved, but thermal contact is reduced
Solution Approach 1:
The thermal management system segments the thermal management function into distinct zones: insulation zones where thermal isolation is prioritized, and contact zones where thermal conduction is prioritized. This segmentation allows the system to achieve both thermal isolation and thermal contact simultaneously in different locations.
Solution Approach 2:
Different thermal management properties are applied locally: insulating material in non-contact regions and thermally conductive material in contact regions. This local quality differentiation resolves the contradiction by allowing both functions to operate optimally in their respective zones.
3Temperature
If thermal conductive material is applied to battery cell surfaces, then thermal contact is improved, but manufacturing complexity increases
Solution Approach 1:
The thermal management layer combines insulation and thermal conduction functions into a single integrated component. This merging eliminates the need for separate insulation material and thermal conductive material applications, thereby reducing manufacturing complexity while maintaining both thermal isolation and thermal contact functions.
Solution Approach 2:
The thermal management layer is designed as a multi-functional component that simultaneously provides thermal insulation, thermal conduction, and mechanical protection. This universality reduces the number of separate components and assembly steps, simplifying the manufacturing process.
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 composition effectively limits exterior temperatures to below 350°C for several minutes during high-temperature incidents, protecting the vehicle and its components from excessive heat.
Implementation Method 1
silicone-based thermal insulation materials for battery modules
Implementation Method 2
The insulation material may comprise a porous core layer and a skin layer
Implementation Method 3
The porous core layer may have a density between 0.05 g/cm³ and 0.2 g/cm³
Data Source
Figure 1
Figure 2~3
AI summary
Metal ion battery modules and battery packs for electric vehicles exhibit highly reduced thermal transfer to areas above the battery modules or battery packs when a top metal cover of the battery modules or battery packs is coated on the side of the cover facing battery modules or individual battery cells, with an addition-curable or moisture-curable ceramifyable organosilicon composition which is sprayable and thixotropic, and contains from 50-85 weight percent of aluminum trihydrate-containing filler, in an amount such that aluminum trihydrate is present in an amount of at least 30 weight percent based on the weight of the organosilicon composition.