Polyurethane Foam Cell Carrier for Thermal Runaway Insulation
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Solution Overview
Problem
Existing cell carriers for immersion cooling do not adequately insulate cells from thermal exposure and provide sufficient burst protection, leading to potential damage from thermal runaway and pressurized gas escape.
Innovation Solution
A cell carrier made of polyurethane foam with a specific mixture of isocyanate, polyol, and ammonium sulfate, featuring high-temperature polyurethane foam, optimized grain sizes and densities, and a surface layer with controlled pore sizes and densities, enhances heat absorption and mechanical stability to prevent cell bursting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional polyurethane foam is used for cell carrier, then the cell carrier provides basic thermal insulation, but the heat absorption capacity is insufficient during thermal runaway
Solution Approach 1:
The patent modifies the chemical composition parameters of the polyurethane foam by incorporating ammonium sulfate and other additives in specific proportions. This changes the thermal properties of the foam, enabling it to absorb significantly more heat during thermal runaway events through decomposition reactions of the additives, thereby resolving the contradiction between basic insulation and high heat absorption capacity.
Solution Approach 2:
The patent creates a composite material system by combining polyurethane foam with ammonium sulfate, mica, and other substances. This composite structure leverages the insulating properties of the foam matrix while the embedded additives provide enhanced heat absorption and thermal stability, simultaneously achieving both thermal insulation and reliable protection against thermal runaway.
2Strength
If conventional polyurethane foam is used for cell carrier, then the cell carrier provides basic structural support, but the mechanical stability during cell bursting is insufficient
Solution Approach 1:
The patent adjusts the density, cross-linking degree, and compositional parameters of the polyurethane foam to optimize its mechanical properties. These parameter changes enhance the foam's compressive strength and structural integrity, enabling it to withstand the pressure waves and physical stress generated during cell bursting events while maintaining adequate protection for surrounding cells.
Solution Approach 2:
The incorporation of mica and other reinforcing additives into the polyurethane foam matrix creates a composite material with superior mechanical strength. This composite structure provides enhanced structural support and resistance to deformation during cell bursting, resolving the contradiction between basic structural support and adequate protection against bursting damage.
3Strength
If the polyurethane foam density is increased to improve mechanical stability, then the structural strength increases, but the heat absorption capacity may be reduced
Solution Approach 1:
The patent employs a composite material strategy where the polyurethane foam matrix provides the structural framework, while dispersed particulate additives (ammonium sulfate, mica) provide the heat absorption function. This composite architecture allows the foam density to be optimized for mechanical strength without compromising heat absorption, as the heat-absorbing additives are distributed throughout the structure and contribute independently to thermal energy dissipation during thermal runaway.
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 provides improved thermal insulation and mechanical stability, preventing cell bursting and reducing thermal exposure damage while maintaining efficient heat absorption, allowing for safer and more stable cell operation.
Implementation Method 1
heat absorption by the ammonium sulfate is also involved. This heat absorption occurs primarily through the breaking down of the ammonium sulfate. The heat is therefore absorbed through a conversion.
Implementation Method 2
In state-of-the-art cell carriers, heat is absorbed by their polyurethane foam. This heat absorption occurs primarily through melting of the polyurethane foam.
Implementation Method 3
it does not liquefy, but rather softens at temperatures above 150°C, preferably above 180°C
Implementation Method 4
it has increased heat absorption capacity due to the carbonization of a matrix
Data Source
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AI summary
Shown and described is a cell carrier (2) for at least one cell (3). The at least one cell (3) has a cell housing (4). The cell carrier (2) has a cell receptacle (11) for the at least one cell (3). The cell carrier (2) is made from a polyurethane foam which comprises an isocyanate and a polyol. The invention solves the problem of thermally and mechanically insulating a cell (3) which is arranged in the cell carrier (2) and which is thermally permeable, sufficiently from its surroundings so that the surroundings are not damaged. This problem is solved in that the polyurethane foam is a mixture containing the isocyanate and a first partial mixture, in that the first partial mixture is a mixture containing the polyol and a second partial mixture, and in that the second partial mixture contains an ammonium sulfate.