Multilayer Battery Insulation Structure for Compact Heat Shielding
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Solution Overview
Problem
The safety of battery packs in electric vehicles is compromised due to thermal runaway and explosion risks from internal short circuits, overcharge, and over-discharge, which can lead to secondary ignition and damage.
Innovation Solution
An insulation device comprising multiple cover layers with integrated functional fillers and additives, providing high insulation performance by optimizing the thickness and material composition of each layer, including polyimide films, aluminum, glass fibers, and aerogel powders, to prevent heat and pressure buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If insulation thickness is increased to improve thermal insulation performance, then thermal insulation is improved, but device complexity and space occupation increase
Solution Approach 1:
The patent employs a multi-layer composite insulation structure consisting of a first cover layer (10 μm to 50 μm thick polymer film), a second cover layer (10 μm to 50 μm thick aluminum or mica layer), and a third cover layer (0.1 mm to 1.5 mm thick porous insulation material). This composite structure achieves superior thermal insulation performance with reduced overall thickness compared to single-material solutions, as each layer contributes different thermal barrier properties synergistically.
Solution Approach 2:
The third cover layer utilizes porous insulation materials such as glass fiber, silica wool, mineral wool, ceramic wool, or non-woven fabric with density of 30 g/m2 to 200 g/m2. The porous structure provides high thermal resistance by trapping air pockets that inhibit heat conduction, achieving effective thermal insulation with minimal material thickness and reduced overall device complexity.
2Temperature
If functional filler density is increased to improve insulation effectiveness, then thermal insulation is improved, but weight increases
Solution Approach 1:
The third cover layer employs porous materials with controlled density (30 g/m2 to 200 g/m2) that provide high thermal insulation performance per unit weight. The porous structure creates air pockets that significantly reduce thermal conductivity, allowing effective insulation with lightweight materials rather than dense, heavy alternatives.
Solution Approach 2:
The multi-layer composite structure distributes insulation functionality across different materials optimized for their specific strengths: thin polymer films for structural integrity, metallic or mica layers for radiant heat barrier, and porous materials for convective and conductive heat resistance. This distribution achieves superior insulation effectiveness without concentrating weight in a single heavy component.
3Volume of moving object
If cover layer thickness is reduced to maintain compact design, then energy density is improved, but insulation performance deteriorates
Solution Approach 1:
The patent achieves effective thermal insulation in a compact thickness (total average thickness 4 mm or less) by employing a multi-layer composite structure where each layer contributes specific thermal barrier properties. The combination of thin polymer films (10-50 μm), metallic/mica layers (10-50 μm), and porous insulation (0.1-1.5 mm) creates synergistic thermal resistance that exceeds the sum of individual layers, enabling high insulation performance in reduced thickness.
Solution Approach 2:
The third cover layer uses porous insulation materials with optimized density (30 g/m2 to 200 g/m2) that provide exceptional thermal resistance per unit thickness. The porous structure traps air pockets that act as thermal barriers, allowing effective insulation performance to be achieved with minimal material thickness, thus maintaining compact overall device dimensions.
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 insulation device effectively enhances the safety of battery modules and packs by improving thermal insulation and preventing explosions, while maintaining a lightweight and compact design that does not compromise energy density.
Implementation Method 1
the insulation part may include a functional filler... A filling density of the functional filler included in the insulation part may be 0.05 g/cm3 to 0.20 g/cm3 range
Implementation Method 2
The second cover layer may include at least one of aluminum and mica
Implementation Method 3
The third cover layer may include at least one of a glass fiber, a silica wool, a mineral wool, a ceramic wool
Data Source
AI summary
An insulation device for a battery according to an embodiment includes: a first cover layer including a first hole; a second cover layer attached to one surface of the first cover layer and including a second hole; and a third cover layer disposed on the opposite surface to which the first cover layer is attached on the second cover layer, wherein the insulation device may include an insulation part inside, and the insulation part may include a functional filler.