Integrated Thermal Barriers for Traction Battery Array Isolation

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Solution Overview

Problem

High voltage traction battery packs in electrified vehicles face challenges in mitigating the effects of battery thermal events, such as heat transfer and gas venting between battery arrays, which can lead to structural integrity issues and electrical shorting.

Innovation Solution

The integration of a thermal barrier system featuring a foam portion and an endothermic aerogel system, including bifurcation structures, canopy structures, and thermal barrier plates, which are designed to isolate battery arrays and prevent heat and gas transfer, using materials like polyurethane foam and a high-temperature endothermic aerogel system with additives like melamine powder and intumescent materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If battery arrays are placed in close proximity to maximize space utilization, then productivity and space efficiency are improved, but heat transfer and gas venting between arrays increase, worsening thermal safety and reliability

Engineering Contradiction:

Improvespace utilizationVSAvoidthermal safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The battery pack is divided into multiple battery arrays with thermal barrier components positioned between them. The thermal barrier system includes foam portions and endothermic aerogel systems that segment the thermal pathways, preventing heat and gas transfer while maintaining close proximity of arrays for space efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Thermal barrier components serve as intermediary elements positioned between adjacent battery arrays. These components include foam portions and endothermic aerogel systems that mediate thermal and gas transfer, blocking harmful effects while allowing the arrays to remain in close proximity for optimized space utilization.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If thermal barrier components are added between battery arrays to prevent heat and gas transfer, then reliability and thermal safety are improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvethermal safetyVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Thermal barrier components are applied locally at critical interfaces between battery arrays rather than throughout the entire battery pack. The foam portions and endothermic aerogel systems are positioned specifically where heat and gas transfer risks exist, providing targeted thermal protection without adding unnecessary complexity to the overall structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The thermal barrier system combines foam materials with endothermic aerogel systems to create a composite structure that provides both thermal insulation and heat absorption capabilities. This composite approach enhances thermal safety while consolidating multiple functions into integrated components, reducing overall structural complexity.

Inventive Principle:

Principle #40Composite materials

3Temperature

If foam portions and endothermic aerogel systems are integrated into thermal barrier components, then thermal protection capability is improved, but manufacturing precision and assembly difficulty increase

Engineering Contradiction:

Improvethermal protection capabilityVSAvoidassembly precision

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The foam portion and endothermic aerogel system are merged into a single integrated thermal barrier component. This combination consolidates thermal insulation and heat absorption functions into one unit, simplifying the assembly process and reducing the number of separate manufacturing steps required while maintaining enhanced thermal protection capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The thermal barrier components are designed to perform multiple functions simultaneously: thermal insulation, heat absorption, and gas blocking. By integrating foam portions with endothermic aerogel systems, a single component achieves universal thermal protection, reducing assembly complexity and improving manufacturing efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Effectively mitigates the effects of battery thermal events by preventing heat and gas transfer between battery arrays, thereby protecting the structural integrity of the enclosure and preventing electrical shorting, while withstanding high temperatures and maintaining operational safety.

Implementation Method 1

endothermic aerogel system

Methodology Applied

Scientific EffectEndothermic reaction: Endothermic Reaction

Implementation Method 2

foam portion

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

intumescent additive

Methodology Applied

Scientific EffectIntumescence: Intumescent Materials

Data Source

PatentUS20240170767A1Traction battery packs with integrated thermal barrier systems

Publication Date: 2024.05.23 FORD GLOBAL TECH LLC

AI summary

Battery thermal barrier systems are provided for traction battery packs. Exemplary battery thermal barrier systems may include one or more components that include a foam portion and an endothermic aerogel system configured to mitigate the effects of battery thermal events. The components may include bifurcation structures, canopy structures, thermal barrier plates, or combinations thereof.