Silicate Thermal Barrier Coating for Battery Pack Heat Isolation
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Solution Overview
Problem
Electrified vehicle battery packs face challenges in efficiently managing heat dissipation, as conventional heat exchangers may not adequately control temperature, leading to potential thermal issues and reduced performance.
Innovation Solution
A silicate-based thermal barrier coating and layer system is applied to the battery pack housing, comprising sodium silicate, thermal barrier particles, and non-ionic surfactants, which is integrated with a substrate and thermal barrier layers to create a multi-layered insulation structure, including fabric or foam layers, to effectively block heat emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heat exchangers and coolant circuits are used for heat removal, then heat dissipation is achieved, but thermal management effectiveness is insufficient leading to potential thermal issues
Solution Approach 1:
The patent applies composite materials by combining silicate-based thermal barrier coating with ceramic particles (such as alumina, magnesia, or zirconia) embedded in a silicate matrix. This composite structure provides superior thermal insulation properties compared to conventional single-material heat exchangers, effectively blocking heat transfer while maintaining structural integrity for reliable thermal management
Solution Approach 2:
The silicate-based thermal barrier coating acts as an intermediary layer between the battery cells and the external environment. This coating layer mediates heat transfer by providing thermal insulation while allowing the heat exchanger system to function, thereby enhancing overall thermal management effectiveness without requiring complete redesign of existing coolant circuits
2Productivity
If heat exchanger cold plates and coolant circuits are used for heat removal, then heat dissipation is achieved, but thermal issues persist reducing performance
Solution Approach 1:
The patent applies local quality by positioning the silicate-based thermal barrier coating specifically at critical heat generation zones and interfaces within the battery pack, such as between battery cells and housing, or at locations with highest thermal flux. This targeted approach optimizes thermal control effectiveness where it is most needed, thereby maintaining battery performance without excessive heat accumulation
3Object-generated harmful factors
If thermal barrier coating is applied to block heat emission, then heat transfer to exterior is reduced, but coating material must be chemically resistant and non-corrosive
Solution Approach 1:
The silicate-based composite coating combines chemically inert silicate matrix with stable ceramic particles, creating a material that is both thermally insulating and chemically resistant. This composite structure prevents corrosion while blocking heat emission, maintaining reliability in the harsh battery pack environment
Solution Approach 2:
The silicate-based coating creates a chemically inert barrier layer between the metal components and the corrosive battery environment. This inert protective layer prevents chemical reactions and corrosion while simultaneously providing thermal insulation, thereby reducing heat emission without compromising chemical resistance
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 significantly reduces heat transfer to the exterior, maintaining optimal battery temperatures and preventing thermal damage, while being chemically resistant and non-corrosive, thus enhancing battery pack performance and longevity.
Implementation Method 1
a silicate-based thermal barrier coating configured to block heat emitted from the battery pack
Data Source
AI summary
An article, such as a battery pack system, includes a battery pack that is comprised of a plurality of battery cells. An external housing covers at least a portion of the battery pack. A silicate-based thermal barrier coating is configured to block heat emitted from the battery pack.