Plastic Battery Casing with Thermal Conductive Fillers
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Solution Overview
Problem
Energy storage systems, particularly lithium-ion batteries, face significant challenges with thermal runaway, where high temperatures can lead to damage and heat propagation among adjacent cells, especially in high-energy-density applications like electric vehicles, due to limited thermal management capabilities.
Innovation Solution
The use of a plastic casing with enhanced thermal conductivity materials, such as ceramic fillers or endothermic compounds, to absorb and dissipate heat effectively, preventing excessive temperature transfer to adjacent cells during thermal runaway events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If energy storage systems use high energy density with many storage cells in narrow space, then the electrical energy capacity increases, but the risk of thermal runaway and heat propagation to adjacent cells increases
Solution Approach 1:
The patent introduces a casing made of plastic with embedded heat-conducting material as an intermediary between storage cells. This intermediary structure serves dual purposes: providing electrical insulation while actively conducting heat away from individual cells to prevent thermal propagation, thereby enabling high energy density without proportionally increasing thermal risk
Solution Approach 2:
The patent employs composite materials by combining plastic (for electrical insulation and structural properties) with heat-conducting material (for thermal management). This composite casing simultaneously addresses both the need for electrical isolation and active heat dissipation, resolving the contradiction between energy density and thermal safety
2Reliability
If cooling devices are arranged between storage cells to prevent thermal propagation, then thermal safety improves, but device complexity and space requirements increase
Solution Approach 1:
The patent makes the casing multi-functional by combining structural support, electrical insulation, and active heat conduction functions into a single component. This eliminates the need for separate cooling devices between cells, reducing structural complexity while maintaining thermal safety through the heat-conducting material integrated into the casing
Solution Approach 2:
The patent merges the functions of structural casing and thermal management system into a single integrated component. The plastic casing with embedded heat-conducting material combines mechanical protection, electrical insulation, and heat dissipation functions, thereby reducing device complexity compared to separate cooling devices
3Ease of manufacture
If plastic casing is used for storage cells, then ease of manufacture and cost decrease, but thermal conductivity is insufficient for effective heat dissipation
Solution Approach 1:
The patent creates a composite casing by embedding heat-conducting material within the plastic matrix. This composite structure maintains the manufacturing advantages and cost benefits of plastic while adding thermal conduction capability, thereby resolving the contradiction between ease of manufacture and heat dissipation performance
Solution Approach 2:
The patent applies local quality enhancement by selectively embedding heat-conducting material in specific regions of the plastic casing where heat dissipation is most needed. This localized approach maintains overall manufacturing simplicity while providing targeted thermal management where required
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 solution effectively manages heat dissipation and prevents thermal propagation, ensuring operational reliability and safety by maintaining adjacent cell temperatures below harmful levels, even during extreme thermal events.
Implementation Method 1
the casing is provided with a material for increasing a thermal conductivity
Implementation Method 2
endothermic compounds, to absorb and dissipate heat effectively
Data Source
AI summary
An energy storage system includes at least one storage cell. The at least one storage cell is provided, at least in sections, with a casing. The casing consists of plastic, and the casing is provided with a material for increasing a thermal conductivity.