Core-Sheath Binder Fiber Sheet for Battery Pack Heat Insulation
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Solution Overview
Problem
Existing heat insulation sheets for battery packs face challenges in maintaining high strength and preventing powder falling, which can lead to decreased heat insulation performance and potential thermal runaway.
Innovation Solution
A method for producing a heat transfer suppression sheet using a dry method with a binder fiber having a core-sheath structure, where the core portion has a higher melting point than the sheath portion, allowing for improved retention of inorganic particles and enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wet papermaking method is used to produce heat insulation sheet, then the binder fiber can be kept in wet state to exhibit adhesiveness, but dry silica aggregates with water and thermal conductivity increases
Solution Approach 1:
The patent changes the physical state parameter of the inorganic particle from dry to wet form (wet silica), and adjusts the binder fiber properties to work in wet state, enabling the use of wet papermaking method while maintaining heat insulation performance through controlled water content and material selection
Solution Approach 2:
The patent creates a composite material system combining wet silica particles with binder fibers and optional hydrophobic agents, where the components work together to prevent aggregation and maintain low thermal conductivity while enabling wet processing
2Reliability
If dry molding method is used to produce heat insulation sheet, then the inorganic particle does not aggregate, but the inorganic particle may fall off due to pressure or impact
Solution Approach 1:
The patent introduces binder fibers as an intermediary material that bonds inorganic particles together, creating a matrix structure that prevents particle fall-off under pressure or impact while maintaining the dry state and low thermal conductivity of the inorganic particles
Solution Approach 2:
The patent creates a composite material structure where binder fibers form a reinforcing matrix that holds inorganic particles in place, combining the low thermal conductivity of dry inorganic particles with the mechanical strength of the fiber matrix
3Ease of manufacture
If the heat insulation sheet has low strength, then the production process is simpler, but the heat insulation sheet is compressed by battery cell expansion and powder falling occurs
Solution Approach 1:
The patent creates a composite material with high compressive strength by combining binder fibers with inorganic particles, enabling the heat insulation sheet to resist compression from battery cell expansion during charging and discharging cycles
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 resulting heat transfer suppression sheet achieves both excellent strength and heat insulation performance, effectively preventing powder falling and maintaining thermal integrity even under compressive stress.
Implementation Method 1
a melting point of a first organic material constituting the core portion is higher than a melting point of a second organic material constituting the sheath portion
Data Source
AI summary
A method for producing a heat transfer suppression sheet contains processing a mixture into a sheet by a dry method, the mixture containing an inorganic particle and a binder fiber having a core-sheath structure. The binder fiber having a core-sheath structure includes a core portion extending in its longitudinal direction, and a sheath portion formed to cover an outer peripheral surface of the core portion, and a melting point of a first organic material constituting the core portion is higher than a melting point of a second organic material constituting the sheath portion.