Wool-Core Battery Spacer for Cell Expansion and Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery protective elements fail to effectively manage the expansion of prismatic battery cells during charging, leading to potential deformation of the battery housing, and do not adequately address thermal and electrical stability, recyclability, and environmental concerns.
Innovation Solution
A multi-layer protective element with a compressible core layer made of vegetable or animal wool, such as sheep's wool, combined with mica barrier layers and an adhesive layer, providing thermal insulation, high electrical dielectric strength, and environmental sustainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a compressible core layer with low Shore hardness plastic is used to compensate for battery cell expansion, then the battery cell expansion is compensated and housing deformation is prevented, but the thermal insulation performance is insufficient and electrical dielectric strength is not adequate
Solution Approach 1:
The protective element uses a composite structure combining a compressible core layer (for expansion compensation) with outer layers made of thermally insulating and electrically insulating materials. This composite approach allows simultaneous achievement of mechanical compliance and thermal/electrical safety, resolving the contradiction between expansion compensation and safety requirements.
2Reliability
If different plastics are used for individual layers of the protective element to optimize specific functions, then the functional performance is improved, but the recyclability and environmental friendliness deteriorate
Solution Approach 1:
The patent employs homogeneous materials (natural fibers such as cotton, hemp, or linen) for the protective element layers, replacing multi-material plastic composites. This homogeneity enables easy separation and recycling while maintaining sufficient functional performance through the natural properties of the fibers for compression, thermal insulation, and electrical insulation.
3Reliability
If natural materials like wool are used for the compressible core layer to improve thermal insulation and recyclability, then thermal insulation and environmental friendliness are enhanced, but the compression behavior and structural stability may be compromised
Solution Approach 1:
The patent optimizes the parameters of natural fiber materials (such as fiber orientation, density, layer thickness, and compression force characteristics) to achieve the desired compression behavior. By adjusting these parameters, the natural materials can provide both excellent thermal insulation and appropriate compression characteristics for compensating battery cell expansion.
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 compensates for battery cell expansion, enhances thermal and electrical safety, and facilitates environmentally friendly recycling by using natural, renewable materials with excellent insulation and recyclable properties.
Implementation Method 1
As the battery cells expand, this core layer is compressed, so that the overall thickness of the battery pack, consisting of the individual battery cells and the protective elements arranged between them, remains virtually unchanged during charging.
Implementation Method 2
very good thermal insulation with low thermal conductivities below 0.05 W/mK can be achieved
Implementation Method 3
high electrical breakdown strength
Data Source
Figure 1~2
AI summary
The invention relates to a multilayer protective element (20) for a battery (1) with at least two battery cells (10) arranged side by side, wherein the protective element (20) can be arranged between the battery cells (10), and wherein the protective element (20) has a compressible core layer (21). According to the invention, the core layer (21) comprises plant or animal wool. The invention also relates to a battery (1) and the use of the protective element (20) for a battery (1).