Foam Battery Cell Potting Compound for Flame Resistance and Low Weight
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Solution Overview
Problem
Existing battery modules lack a potting compound that provides both mechanical stability and flame retardancy while minimizing weight, and existing flame retardant compounds often compromise other desirable characteristics such as stiffness and flexibility.
Innovation Solution
A battery module comprising an electric cell embedded in a foam potting compound formed from a mixture of an isocyanate reactive compound and an isocyanate compound, with a flame retardant component present in at least 15 wt.%, which cures to form a low-density, flame-retardant foam with V2 level flame resistance as measured by the UL 94 Test.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flame retardant compound is added to the potting compound, then flame resistance is improved, but density increases and mechanical properties deteriorate
Solution Approach 1:
The patent employs a foam structure with controlled porosity to reduce the density of the flame retardant potting compound. The foam architecture creates air pockets within the material matrix, lowering overall density while preserving flame retardant performance and maintaining adequate mechanical properties for battery module encapsulation.
2Reliability
If a flame retardant compound is added to the potting compound, then flame resistance is improved, but mechanical stability deteriorates
Solution Approach 1:
The patent utilizes a composite formulation combining flame retardant additives with a foam-based potting compound matrix. This composite approach allows the flame retardant properties to be integrated while the foam structure provides mechanical support, achieving a balance between flame resistance and mechanical stability suitable for battery encapsulation applications.
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 achieves a lightweight battery module with enhanced mechanical stability and flame retardancy, maintaining structural integrity and safety without compromising other desirable characteristics like stiffness and flexibility.
Implementation Method 1
The potting compound is formed from the reaction product of a first component having an isocyanate reactive compound; and a second component having an isocyanate compound
Implementation Method 2
The potting compound may further include a blowing agent, and a liquid flame retardant component present in an amount from about 15 wt. % to about 60 wt. % based on the total weight of the potting compound. The potting compound is a foam after curing.
Data Source
AI summary
A battery module comprising an electric cell and a potting compound associated with the electric cell. The potting compound is formed of a flame retardant component; a first component having an isocyanate reactive compound and water; and a second component having an isocyanate compound. The potting compound is a foam.