Multilayer Flame-Retardant Pad for Battery Thermal Runaway
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Solution Overview
Problem
Secondary batteries, particularly lithium secondary batteries, are prone to overheating, leading to thermal runaway, explosions, and fire propagation, posing significant safety risks, especially in medium- or large-scale modules and packs used in electric vehicles and energy storage systems.
Innovation Solution
A composite pad with a multilayer structure of polymer resin layers, each containing different fire extinguishing materials, is used to suppress fires and explosions by activating at varying temperature ranges, with Al(OH)3 effective at lower temperatures and CaBr2 at higher temperatures, effectively delaying flame propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-layer fire retardant pad is used, then the structure is simple, but the fire suppression effectiveness across different temperature ranges is insufficient
Solution Approach 1:
The fire retardant pad is divided into multiple layers, each containing different fire retardant materials optimized for specific temperature ranges. The first layer contains materials effective at lower temperatures, while the second layer contains materials effective at higher temperatures, creating a segmented defense system that addresses different thermal conditions independently
Solution Approach 2:
The pad uses composite material construction by combining different fire retardant materials (such as aluminum hydroxide, magnesium hydroxide, titanium hydroxide, boron nitride, boron carbide, and silicon oxide) within a polymer resin matrix. This composite approach allows the pad to leverage the complementary properties of various materials to achieve broad-spectrum fire suppression across different temperature regimes
2Reliability
If fire retardant materials are added to the pad, then the fire resistance improves, but the response time during thermal runaway may be delayed
Solution Approach 1:
The pad is pre-configured with multiple layers of fire retardant materials before thermal runaway occurs, with each layer designed to activate at specific temperature thresholds. This preliminary arrangement ensures that as temperature rises during thermal runaway, the appropriate layer activates automatically without requiring additional decision-making or intervention, providing immediate and appropriate response
Solution Approach 2:
The pad utilizes parameter changes in the fire retardant materials themselves, which undergo phase transitions or chemical transformations at specific temperatures. These material parameter changes trigger the fire suppression mechanism automatically based on the thermal conditions, ensuring rapid response aligned with the actual thermal state
3Temperature
If multiple fire retardant materials are used in different layers, then the temperature range coverage improves, but the manufacturing process becomes more complex
Solution Approach 1:
The manufacturing process is segmented into distinct stages for preparing and assembling different layers. Each layer can be prepared separately with its specific fire retardant material composition, then assembled in a defined sequence. This segmentation allows for standardized production of individual layers that can be consistently replicated and combined
Solution Approach 2:
The manufacturing approach leverages parameter changes in the polymer resin matrix and fire retardant materials during processing. By controlling parameters such as curing temperature, pressure, and material ratios, the multi-layer structure can be manufactured efficiently while maintaining the distinct functional properties of each layer
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 composite pad effectively suppresses fire propagation and minimizes damage by exerting a stepwise fire extinguishing effect, enhancing safety in secondary battery modules and packs.
Implementation Method 1
a first polymer resin single layer and a second polymer resin single layer, wherein the first polymer resin single layer includes a fire extinguishing material which takes effect in a lower temperature range than the second polymer resin single layer
Data Source
AI summary
There are provided a flame retardant element for suppressing flame propagation when a fire occurs during the use of a lithium secondary battery, thereby ensuring safety of the secondary battery while in use, a method for manufacturing the flame retardant element, and a secondary battery module and a secondary battery pack comprising the flame retardant element. The proposed flame retardant element is a composite pad having a stack of at least two polymer resin single layers including fire extinguishing materials having different fire extinguishing and flame retardant mechanisms, the composite pad includes a first polymer resin single layer and a second polymer resin single layer, and the first polymer resin single layer includes the fire extinguishing material which takes effect in a lower temperature range than the second polymer resin single layer.