Multilayer Coolant Tube Sleeve for EV Thermal Runaway Protection
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Solution Overview
Problem
Current cooling systems for electric vehicle battery packs face challenges in providing effective thermal insulation, electromagnetic shielding, and resistance to thermal runaway, particularly in indirect cooling systems where separate protective layers are cumbersome and costly to apply.
Innovation Solution
A multilayered protective sleeve for battery pack coolant tubes, comprising an innermost textile layer with interlaced filaments, a composite outer layer with a foil layer, fire-resistant coating, and a fiberglass scrim, which is spiral wrapped and bonded with an adhesive, offering thermal insulation, electromagnetic shielding, and resistance to thermal runaway in a single, easy-to-apply component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate protective layers are applied to coolant tubes, then thermal insulation and electromagnetic shielding are improved, but device complexity and application cost increase
Solution Approach 1:
The patent combines multiple separate protective layers (thermal insulation layer, electromagnetic shielding layer, and fire-resistant layer) into a single integrated multilayered sleeve structure. This single component provides all three protective functions simultaneously, eliminating the need for separate application operations and reducing overall system complexity while maintaining comprehensive protection for coolant tubes.
Solution Approach 2:
The multilayered sleeve is designed as a universal protective component that performs multiple functions: thermal insulation (maintaining coolant temperature), electromagnetic shielding (blocking electromagnetic radiation from batteries), and fire-resistant protection (preventing thermal runaway damage). This multi-functional design replaces multiple specialized components with a single versatile solution.
2Reliability
If multiple separate protective layers are used, then comprehensive protection is achieved, but manufacturing cost and application time increase
Solution Approach 1:
The patent merges multiple protective layers into a single pre-assembled multilayered sleeve structure that can be applied to coolant tubes in one operation. This integration maintains all necessary protective functions while significantly improving application efficiency by eliminating sequential application steps and reducing labor requirements.
Solution Approach 2:
The multilayered sleeve is pre-assembled with all protective layers (thermal insulation, electromagnetic shielding, and fire-resistant layers) bonded together before application to the coolant tube. This preliminary assembly allows the complete protective system to be installed in a single step, improving productivity while ensuring proper layer alignment and bonding.
3Weight of moving object
If plastic coolant tubes are used to reduce cost and weight, then thermal runaway resistance is compromised
Solution Approach 1:
The patent employs a composite multilayered sleeve structure with distinct functional layers: thermal insulation layer (e.g., aerogel or fiberglass), electromagnetic shielding layer (e.g., metallic foil), and fire-resistant layer (e.g., intumescent coating or ceramic-based material). This composite structure provides thermal runaway protection while maintaining the lightweight advantage of plastic coolant tubes.
Solution Approach 2:
The fire-resistant layer in the multilayered sleeve provides beforehand cushioning against thermal runaway by creating a protective barrier that prevents heat and flames from reaching the plastic coolant tube. This pre-established protective layer ensures that even if thermal runaway occurs, the plastic tube remains intact and coolant leakage is prevented.
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 multilayered sleeve effectively maintains the battery pack within a safe temperature range, prevents thermal runaway, and provides electromagnetic shielding, enhancing safety and efficiency while reducing application complexity and cost.
Implementation Method 1
a composite outer layer bonded to the innermost textile layer with an adhesive layer
Implementation Method 2
a foil layer bonded to the adhesive layer
Implementation Method 3
a fire resistant coating bonded to the first thermoplastic film
Data Source
AI summary
A protective sleeve for a battery pack coolant tube of an electric vehicle includes a tubular wall extending along a longitudinal axis between opposite ends. The tubular wall has multiple layers, including an innermost textile layer having filaments interlaced with one another and a composite outer layer overlying the innermost textile layer. The composite layer includes a foil layer and a fire resistant coating overlying the foil layer.