Laminated Battery Thermal Barrier for Runaway Isolation
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Solution Overview
Problem
High specific energy batteries, such as lithium-ion batteries, are susceptible to catastrophic thermal runaway due to conditions like overcharge, over-discharge, and internal short circuits, leading to unsafe temperatures and gas release, posing a significant safety risk.
Innovation Solution
Incorporating laminated elements with heat conducting and intumescent layers into battery modules that passively manage heat by conducting it away during normal operation and reconfiguring to a non-heat conducting state during thermal runaway, thereby isolating affected cells and preventing further temperature increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If high specific energy batteries are used to reduce size and weight, then battery energy density is improved, but thermal runaway susceptibility increases
Solution Approach 1:
The battery pack is divided into modular units with individual thermal management for each module. Thermal runaway isolation barriers are implemented at the module level to segment the propagation path of thermal runaway, allowing high energy density batteries to be used while containing thermal hazards within specific modules.
Solution Approach 2:
Thermal runaway isolation barriers serve as intermediary structures between battery modules. These barriers include heat-resistant materials and cooling channels that mediate thermal transfer, allowing high energy density battery design while preventing uncontrolled thermal propagation between modules.
2Object-affected harmful factors
If active cooling elements are added to manage thermal runaway, then thermal safety is improved, but device weight and complexity increase
Solution Approach 1:
The thermal management system operates passively without requiring external power or active control. Cooling channels utilize natural convection and conduction to dissipate heat, and thermal runaway barriers automatically activate when exposed to high temperatures, eliminating the need for powered cooling elements and reducing system weight.
Solution Approach 2:
Active mechanical cooling systems (pumps, fans, valves) are replaced with passive thermal management structures. The system uses inherent thermal conduction through cooling channels and automatic material responses to temperature changes, substituting complex mechanical systems with simpler thermal field-based solutions.
3Object-affected harmful factors
If thermal runaway isolation barriers are implemented, then thermal propagation is prevented, but manufacturing complexity increases
Solution Approach 1:
The thermal runaway isolation barrier structure serves multiple functions: it provides thermal insulation, structural support, and cooling pathways. This multi-functionality reduces the need for separate components, simplifying the overall manufacturing process while maintaining effective thermal propagation prevention.
Solution Approach 2:
The isolation barriers utilize composite material structures combining heat-resistant ceramics, metals, and polymers in integrated layers. These composite structures achieve superior thermal performance while being manufactured as single integrated components, reducing assembly complexity compared to multiple separate parts.
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
This solution effectively manages thermal runaway by isolating affected battery cells, preventing heat transfer and electrical connections, thus ensuring safety and reducing the risk of catastrophic failures while maintaining a lightweight and cost-effective battery design.
Implementation Method 1
at least one laminated element is configured to: conduct heat away from one or more battery cells during normal operational conditions
Implementation Method 2
reconfigure into a non-heat conducting configuration when exposed to temperatures indicative of thermal runaway of the one or more battery cells
Data Source
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AI summary
A battery includes a thermally conductive housing, a first battery cell enclosed within the thermally conductive housing, and a laminated element enclosed within the thermally conductive housing. The laminated element is in contact with the first battery cell and the thermally conductive housing. The laminated element includes one or more heat conducting layers and one or more intumescent layers. The laminated element is configured to conduct heat generated by the first battery cell from the first battery cell to the thermally conductive housing during normal operational conditions of the first battery cell, and to have, with the first battery cell in a thermal runaway condition, a non-heat conducting configuration.