Dual-Layer Battery Module Frame for Thermal Runaway Resistance
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Solution Overview
Problem
Conventional battery modules face challenges in preventing continuous thermal runaway, which can lead to explosion or ignition due to excessive heat and pressure, requiring a solution that enhances durability and safety while maintaining weight reduction and heat dissipation performance.
Innovation Solution
A battery module design featuring a module frame with a first layer of high melting point material (e.g., stainless steel) forming the inner surface and a second layer of high thermal conductivity material (e.g., aluminum) forming the outer surface, coupled through atomic diffusion joining, to withstand high temperatures and pressures, preventing cascading thermal runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heat-resistant shield structure is applied inside the battery module, then thermal safety is improved, but manufacturing cost increases, manufacturing process becomes complicated, and internal space becomes narrower
Solution Approach 1:
The module frame is constructed as a composite structure with a first layer of heat-resistant material (high melting point) and a second layer of thermally conductive material (lower melting point). This composite material approach provides both thermal resistance and heat dissipation capabilities within a single integrated component, eliminating the need for separate heat-resistant shield structures and reducing manufacturing complexity
Solution Approach 2:
The module frame is designed to perform multiple functions simultaneously: it provides structural support, dissipates heat through the second layer, and resists thermal runaway through the first layer. This multi-functional design eliminates the need for additional dedicated heat-resistant components, simplifying the overall manufacturing process while maintaining thermal safety
2Reliability
If a heat-resistant shield structure is applied inside the battery module, then thermal safety is improved, but internal space of the battery module becomes narrower
Solution Approach 1:
The module frame is constructed as a composite structure with a first layer of heat-resistant material (high melting point) and a second layer of thermally conductive material (lower melting point). This composite material approach provides both thermal resistance and heat dissipation capabilities within a single integrated component, eliminating the need for separate heat-resistant shield structures and reducing manufacturing complexity
Solution Approach 2:
The heat-resistant function and heat dissipation function are merged into a single module frame structure rather than using separate components. The first layer provides thermal resistance while the second layer provides heat dissipation, combining multiple protective functions into one integrated component that does not encroach on internal battery cell space
3Temperature
If the module frame is made of high melting point material, then thermal resistance is improved, but heat dissipation performance deteriorates
Solution Approach 1:
The module frame is constructed as a composite structure with a first layer of heat-resistant material (high melting point) and a second layer of thermally conductive material (lower melting point). This composite material approach provides both thermal resistance and heat dissipation capabilities within a single integrated component, eliminating the need for separate heat-resistant shield structures and reducing manufacturing complexity
Solution Approach 2:
Different regions of the module frame have different material properties optimized for their specific functions: the first layer (inner surface) uses high melting point material for thermal resistance where it contacts battery cells, while the second layer (outer surface) uses highly thermally conductive material for heat dissipation toward the environment. This local differentiation of material quality achieves both thermal resistance and heat dissipation simultaneously
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 module frame maintains its shape during internal ignition, preventing external oxygen contact and minimizing weight, while ensuring heat dissipation and reducing the need for additional heat-resistant structures, thus enhancing safety and durability.
Implementation Method 1
the module frame comprises a first layer and a second layer, and the melting point of the first layer is higher than the melting point of the second layer
Implementation Method 2
the second layer may include aluminum, gold, silver, copper, platinum, or an alloy thereof
Implementation Method 3
the module frame maintains its shape during internal ignition, preventing external oxygen contact
Data Source
AI summary
A battery module includes a battery cell stack in which a plurality of battery cells are stacked in one direction, a module frame that houses the battery cell stack, and an end plate that couples to the module frame and covers the front or rear surface of the battery cell stack. The module frame includes a first layer and a second layer, and the melting point of the first layer is higher than the melting point of the second layer.