Composite Battery Pack Wall for Thermal Isolation and Stiffness
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Solution Overview
Problem
Current battery systems for electric vehicles fail to provide sufficient thermal isolation and structural stiffness while minimizing weight, leading to potential thermal runaway and compromised structural integrity during abnormal operations.
Innovation Solution
A multi-layered battery pack wall comprising a phyllosilicate mineral or ceramic insulating layer, a metallic layer, and a polymer insulating layer, designed to distribute heat and maintain structural integrity, with each layer optimized for thermal, electrical, and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a single-layer housing is used, then the weight is minimized, but the thermal isolation and structural stiffness are insufficient
Solution Approach 1:
The housing employs a multi-layer composite structure consisting of alternating insulating layers (polymer or ceramic) and metallic layers. The insulating layers provide thermal isolation to prevent heat transfer, while the metallic layers provide structural stiffness and strength. This composite approach achieves both thermal protection and structural integrity without requiring excessive weight, as each layer is optimized for its specific function.
Solution Approach 2:
The housing is divided into multiple discrete layers with distinct functions. The insulating layers are segmented from the metallic layers, allowing each to perform its specialized role independently. This segmentation enables the insulating layers to focus on thermal isolation while the metallic layers focus on structural support, achieving both goals more effectively than a monolithic structure.
2Reliability
If thermal isolation is enhanced with thicker insulating layers, then thermal runaway risk is reduced, but structural stiffness and strength are compromised
Solution Approach 1:
The multi-layer composite structure combines insulating materials (polymer or ceramic) with metallic materials in alternating layers. The insulating layers provide the necessary thermal isolation to prevent thermal runaway, while the metallic layers restore and maintain the structural stiffness and strength that would otherwise be compromised by thick insulating material alone. This composite approach allows both thermal protection and structural integrity to be achieved simultaneously.
Solution Approach 2:
Different regions of the housing have different properties tailored to their specific functions. The insulating layers are positioned where thermal isolation is most critical (adjacent to battery cells), while the metallic layers are positioned where structural strength is needed (outer surfaces and load-bearing areas). This local differentiation of material properties optimizes both thermal protection and structural strength.
3Strength
If metallic layers are added for structural stiffness, then housing strength is improved, but thermal isolation performance is reduced
Solution Approach 1:
The housing uses a multi-layer composite structure where metallic layers and insulating layers are combined in alternating sequence. The metallic layers provide the necessary structural stiffness and strength for housing integrity, while the insulating layers (polymer or ceramic) are positioned between the metallic layers and the battery cells to provide thermal isolation. This composite structure allows both structural strength and thermal isolation to coexist without compromising either function.
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 effectively isolates thermal energy, prevents heat concentration, and maintains structural integrity, reducing the risk of thermal runaway and enhancing the safety and performance of battery systems in electric vehicles.
Implementation Method 1
a first insulating layer that comprises a phyllosilicate mineral and/or a ceramic and that is between the plurality of battery modules and a first metallic layer
Implementation Method 2
a second insulating layer that comprises a polymer and that is between the first metallic layer and a second metallic layer
Data Source
AI summary
A battery pack includes a housing configured to house one or more battery packs comprising battery cells, the housing including a plurality of walls. at least one of the plurality of walls includes a first insulating layer comprising a phyllosilicate mineral and/or a ceramic; a first metallic layer connected to the first insulating layer; a second insulating layer connected to the first metallic layer; and a second metallic layer connected to the second insulating layer.