Interlocking Barrier Sheets for Battery Thermal Propagation Resistance
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Solution Overview
Problem
High-voltage battery modules face increased risk of thermal events due to internal cell defects, which can propagate to adjacent cells, necessitating a heat- or fire-resistant barrier without increasing module size or weight, and requiring adaptability for varying cell numbers and form factors.
Innovation Solution
A barrier structure comprising interlocking first and second sidewalls forming a grid pattern around cylindrical battery cells, made from materials like plastic, meta-aramid fibers, or ceramic fiber paper, which can be easily adapted to different configurations and provides thermal insulation and electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are packaged closely to increase energy density, then the energy density of the battery module is improved, but the risk of thermal event propagation between adjacent cells increases
Solution Approach 1:
The patent introduces a barrier sheet as an intermediary component positioned between adjacent battery cells. This barrier sheet acts as a thermal and electrical isolator, preventing direct contact and heat transfer between cells while maintaining the compact packaging arrangement. The barrier sheet material and structure are specifically designed to block thermal propagation pathways without requiring significant additional space.
Solution Approach 2:
The patent employs thin film barrier sheets with flexible structures that can be inserted between closely packed cells. These thin films provide thermal and electrical isolation while occupying minimal volume, allowing the battery module to maintain high energy density. The flexible nature of these films enables them to conform to the cell surfaces and fill gaps in the compact arrangement.
2Object-affected harmful factors
If flame retardant potting material is used to provide thermal barriers, then thermal event propagation is prevented, but the weight and size of the battery module increase significantly
Solution Approach 1:
The patent replaces bulky flame retardant potting material with thin film barrier sheets that provide equivalent or superior thermal isolation. These thin films reduce the volume and weight of barrier material required while maintaining effective thermal blocking. The high thermal resistance per unit thickness of the barrier sheet material allows for minimal material usage.
Solution Approach 2:
The patent utilizes composite barrier sheet materials that combine high thermal resistance with low density and thin profile. These composite materials achieve flame retardancy and thermal isolation properties without the weight penalty of traditional potting compounds. The multi-layer or multi-component structure of the barrier sheet provides enhanced thermal blocking efficiency at reduced thickness.
3Object-affected harmful factors
If fixed barrier structures are used for thermal isolation, then thermal propagation is prevented, but the adaptability to different cell numbers and form factors is reduced
Solution Approach 1:
The patent employs barrier sheets with dynamic and flexible characteristics that allow them to adapt to different cell arrangements. The barrier sheets can be cut, folded, or shaped to match various cell configurations, numbers, and form factors. This flexibility enables the same barrier sheet design to be used across multiple battery module designs without requiring custom rigid structures for each configuration.
Solution Approach 2:
The patent designs universal barrier sheets that can serve multiple battery cell configurations and form factors. The barrier sheet structure and material properties are designed to provide effective thermal isolation across different cell sizes, arrangements, and module designs. This universality allows a single barrier sheet design to be applied to various battery module specifications, enhancing adaptability and reducing design complexity.
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 event propagation between battery cells while maintaining module compactness and flexibility for various cell arrangements, offering both fire resistance and electrical insulation.
Implementation Method 1
heat- or fire-resistant barrier between cells to reduce or prevent propagation of a thermal event
Implementation Method 2
provides thermal insulation and electrical isolation
Data Source
AI summary
A barrier structure, a battery module including the barrier structure, and a method of assembling the battery module are provided. The barrier structure includes a plurality of first sidewalls oriented in a first direction, and a plurality of second sidewalls oriented in a second direction. The plurality of first sidewalls interlock with the plurality of second sidewalls to form a grid structure comprising a plurality of cells, each having an open-ended top and an open-ended bottom and configured to be arranged around a cylindrical section of at least one of a plurality of battery cells. The battery module includes a plurality of cylindrical battery cells arranged in a predetermined pattern and a barrier structure for separating the battery cells.