Fusible Thermal Interface Material for Battery Thermal Isolation

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Solution Overview

Problem

Traction battery packs face challenges in managing thermal energy transfer during battery thermal events, leading to potential overheating and thermal propagation issues within the pack.

Innovation Solution

Incorporating a fusible thermal interface material between battery cells and a heat exchanger plate, which transitions from a conductor to an insulator at a predefined temperature threshold, either by disintegrating to create an air gap or expanding to form an insulating barrier, thereby limiting thermal energy transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a thermal interface material maintains thermal contact between battery cells and heat exchanger plate, then heat dissipation efficiency is improved, but thermal propagation risk increases during thermal events

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidthermal propagation risk

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The thermal interface material transitions from a static thermal conductor to a dynamic system that changes its thermal properties based on temperature. During normal operation, the material maintains thermal conductivity for heat dissipation. During thermal events exceeding the melting point, the material melts and transforms into an insulating barrier, dynamically adapting to prevent thermal propagation while maintaining structural integrity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention utilizes a phase change material whose thermal conductivity parameter changes dramatically at a specific temperature threshold (melting point). Below the melting point, the material exhibits high thermal conductivity for efficient heat transfer. Above the melting point, the material transitions to a low thermal conductivity state, automatically adjusting the thermal parameter to prevent overheating and thermal propagation.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If a fusible thermal interface material is used to limit thermal energy transfer, then thermal propagation is prevented, but thermal contact is lost during normal operation

Engineering Contradiction:

Improvethermal propagation preventionVSAvoidthermal contact maintenance

Core Design Contradiction:

Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The invention employs a fusible thermal interface material that undergoes a phase transition from solid to liquid at a predefined melting point. During normal operation below the melting point, the material remains solid and maintains thermal contact. When temperature exceeds the melting point during thermal events, the material melts and forms an insulating barrier, using the phase transition to automatically switch between thermal contact and thermal isolation modes.

Inventive Principle:

Principle #36Phase transitions

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

Effectively prevents thermal energy propagation and overheating by maintaining thermal contact during normal conditions and isolating heat during thermal events, enhancing the safety and efficiency of the battery pack.

Implementation Method 1

a fusible thermal interface material disposed between the plurality of battery cells and the heat exchanger plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the fusible thermal interface material is configured to transition from a conductor to an insulator when a temperature within the traction battery pack exceeds a predefined temperature threshold

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 3

at least a portion of the fusible thermal interface material is configured to disintegrate to establish an insulating air gap between the plurality of battery cells and the heat exchanger plate when the temperature exceeds the predefined temperature threshold

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20240079672A1Fusible thermal interface materials for use within traction battery packs

Publication Date: 2024.03.07 FORD GLOBAL TECH LLC

AI summary

Fusible thermal interface materials are provided for traction battery packs. An exemplary fusible thermal interface material may be disposed between a grouping of battery cells and a heat exchanger plate for limiting the transfer of thermal energy associated with a battery thermal event from moving from cell-to-cell and/or compartment-to-compartment within the traction battery pack. The fusible thermal interface material may be configured to transition from a conductor to an insulator when a temperature exceeds a predefined temperature threshold.