Polymeric Core Thermal Shield for EV Battery Heat Flow
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Solution Overview
Problem
Conventional heat shields made of high thermal conductivity metals fail to effectively reduce heat flow between the shielded and unshielded sides, particularly in applications with limited space, such as in electric vehicles, where weight and efficiency are concerns, and there is a need for reduced thermal conductivity, weight, and enhanced thermal management.
Innovation Solution
A thermal shielding device comprising a composite material with a polymeric core layer between two metal layers, which increases separation and thickness upon heating, reducing thermal conductivity and absorbing thermal energy through endothermic reactions, while also providing flame retardation and sound dampening properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional heat shields are made from metal sheets with high thermal conductivity, then the heat shield provides a direct barrier for flame propagation, but heat quickly flows from one side to another, failing to reduce heat flow effectively
Solution Approach 1:
The patent applies composite materials by combining metal layers with polymeric core layers to create a multi-layer structure. The metal layers provide flame barrier capability while the polymeric core layers with low thermal conductivity reduce heat flow, resolving the contradiction between maintaining flame protection and reducing heat transmission.
Solution Approach 2:
The patent applies local quality by assigning different functional properties to different layers of the composite structure. Metal layers are positioned where flame barrier capability is needed, while polymeric core layers are positioned where heat flow reduction is prioritized, allowing each material to perform its optimal function in the appropriate location.
2Object-affected harmful factors
If heat shields are made from materials that reduce thermal conductivity, then heat flow is reduced, but the shielding device weight increases
Solution Approach 1:
The patent uses composite materials combining lightweight polymeric core layers with thin metal layers. This composition achieves low thermal conductivity for heat flow reduction while maintaining low overall weight, as the polymeric materials are significantly lighter than solid metal shields would be.
Solution Approach 2:
The patent applies parameter changes by optimizing the thickness and thermal conductivity parameters of each layer. The polymeric core layers have thickness and material properties selected to achieve the desired thermal insulation performance while keeping the overall device weight within acceptable limits.
3Volume of moving object
If the spacing between battery cells and passenger compartment is minimized for space efficiency, then vehicle space utilization improves, but heat quickly flows from the battery side to the passenger compartment
Solution Approach 1:
The patent applies composite materials in the form of multi-layer thermal shielding devices that can be installed in minimal space between battery cells and the passenger compartment. These composite structures provide effective heat flow reduction despite the limited spacing available.
Solution Approach 2:
The patent applies parameter changes by using materials and structures optimized for thin-profile applications. The thermal shielding device maintains very small thickness parameters while achieving effective heat flow reduction, enabling installation in the limited space available in modern vehicle designs.
4Object-affected harmful factors
If the polymeric core layer generates gas at high temperature, then the separation between metal layers increases and thickness increases by 15 percent or more, but the device complexity increases
Solution Approach 1:
The patent applies phase transitions by incorporating polymeric core layers that undergo thermal decomposition and gas generation at elevated temperatures. This phase change mechanism enables the layers to separate and increase thickness in response to thermal events, providing enhanced thermal management through a relatively simple compositional change rather than complex mechanical systems.
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 reduces heat flow, minimizes weight, and enhances thermal management by increasing separation between metal layers, absorbing thermal energy, and providing additional protective features like flame retardation and sound dampening, addressing the limitations of conventional heat shields.
Implementation Method 1
absorption of energy via an endothermic reaction
Implementation Method 2
increase in separation between the metal layers following an extreme thermal event
Data Source
AI summary
The teachings herein relate to thermal shielding devices for reducing and/or delaying heating of a region near a heat source. The thermal shielding device is preferably formed of a composite material. The composite material preferably has a core layer that is generally thermally insulating.