Composite Battery Pack Partition Wall for Thermal Runaway Blocking
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Solution Overview
Problem
Existing battery packs face the risk of thermal runaway due to abnormal heat generation in one cell causing adjacent cells to ignite, with mica plates failing to prevent burning once the plastic holder melts.
Innovation Solution
A battery pack design featuring a three-layer partition wall with a non-melting plate inside a resin molded layer, which absorbs heat from an overheating cell while maintaining structural integrity, and inflow spaces to channel melted resin away from adjacent cells, preventing thermal runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a plastic holder is used to arrange battery cells at fixed positions, then the battery cells can be arranged at fixed positions, but the holder would melt under abnormal heat and fail to partition adjacent battery cells
Solution Approach 1:
The partition wall is constructed as a composite structure with a non-melting plate (mica or metal) as the core layer providing thermal resistance, and resin molded layers on both surfaces providing structural integrity and cell arrangement functionality. This composite structure combines the heat-resistant properties of inorganic materials with the structural advantages of plastic, solving the contradiction between ease of arrangement and thermal reliability.
2Reliability
If a mica plate is disposed between adjacent battery cells to insulate heat, then thermal insulation is improved, but the structure cannot be mass-produced inexpensively as a single-piece plastic structure
Solution Approach 1:
The invention merges the thermal insulation function of the mica plate with the structural function of the plastic holder into a single integrated partition wall component. The resin molded layers are laminated directly onto both surfaces of the non-melting plate, creating a unified structure that can be molded as a single piece, thereby reducing manufacturing steps and costs while maintaining both thermal insulation and structural integrity.
Solution Approach 2:
By creating a composite structure where resin layers are bonded to the mica plate surfaces, the invention achieves both excellent thermal insulation properties and ease of mass production through single-piece molding, resolving the contradiction between reliability and manufacturing ease.
3Quantity of substance
If battery cells are arranged without gap to increase capacity, then the capacity is increased, but the risk of thermal runaway propagation increases
Solution Approach 1:
The partition wall acts as an intermediary barrier between adjacent battery cells. The non-melting plate layer provides thermal insulation that blocks heat transfer between cells, while the resin molded layers provide structural support and maintain the no-gap arrangement. This intermediary structure allows high-density cell arrangement while preventing thermal runaway propagation.
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 by using a non-melting plate and resin molded layers to insulate and channel away heat, ensuring adjacent cells are not affected by abnormal heat, even when the holder melts.
Implementation Method 1
the resin molded layer laminated on one surface of the non-melting plate will thermally melt with the battery cell having generated abnormal heat and absorbs the heat of melting
Implementation Method 2
the non-melting plate and the resin molded layer on the one surface protect the adjacent battery cells, thereby preventing induction of thermal runaway
Data Source
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AI summary
A battery pack includes a plurality of battery cells (1) and holder (2) that has battery cells (1) arranged in a parallel posture. Holder (2) has partition wall (23) between adjacent battery cells (1) for arranging battery cells (1) at fixed positions. Partition wall (23) has a surface facing battery cells (1) as resin molded layer (12) shaped to arrange battery cells (1) at the fixed positions. Partition wall (23) has a three-layer structure that non-melting plate (13) is disposed inside and resin molded layer (12) is laminated on both surfaces of non-melting plate (13). Holder (2) is formed in a single-piece structure by molding resin molded layer (12) from a synthetic resin.