Wool-Core Battery Protective Layer for Cell Expansion Insulation
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Solution Overview
Problem
Existing battery protective elements fail to adequately address the expansion of battery cells during charging, leading to potential deformation and damage of the battery housing, while also requiring materials that provide thermal and electrical shielding, high dielectric strength, and environmental sustainability.
Innovation Solution
A multi-layered protective element with a compressible core layer predominantly made of animal wool, such as sheep's wool, which provides excellent thermal insulation, compressibility, and environmental friendliness, combined with mica barrier layers for thermal and electrical shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a compressible core layer made of soft plastics material is used to compensate for battery cell expansion, then the battery housing deformation is prevented, but the thermal insulation performance is insufficient
Solution Approach 1:
The protective element combines a compressible core layer made of thermally insulating material with outer layers providing mechanical protection and thermal barrier functions. This composite structure simultaneously achieves both compression capability for expansion compensation and superior thermal insulation performance, resolving the contradiction between mechanical stability and thermal protection.
2Reliability
If different plastics materials are used for individual layers of the protective element to optimize performance, then the functional requirements are met, but the recyclability is compromised
Solution Approach 1:
The protective element is designed with layers made from the same or compatible plastics materials, enabling the entire assembly to be recycled together as a single material type. This homogeneity approach maintains functional performance through optimized layer design while ensuring environmental friendliness and ease of recycling, resolving the contradiction between performance optimization and recyclability.
3Reliability
If the protective element provides adequate thermal shielding to prevent thermal runaway propagation, then the safety is improved, but the material selection becomes more restricted
Solution Approach 1:
The protective element employs a composite structure with specific material properties selected for each layer to achieve thermal shielding functionality. The core layer uses thermally insulating material with specific conductivity characteristics, while outer layers provide additional thermal and mechanical protection, creating a multi-functional system that meets safety requirements while maintaining material selection flexibility through the composite approach.
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 mitigates the expansion of battery cells, provides reliable thermal and electrical shielding, and ensures environmental sustainability by using recyclable and renewable materials, thereby enhancing the safety and recyclability of batteries.
Implementation Method 1
the protective element arranged between two adjacent battery cells has a compressible core layer. When the battery cells expand, this core layer is compressed so that the total thickness of the battery pack practically does not change
Implementation Method 2
very good thermal insulation can be achieved with low thermal conductivities below 0.05 W/mK
Implementation Method 3
the protective element should have low thermal conductivity, high dielectric strength and high thermal (fire) resistance
Data Source
AI summary
The invention relates to a multi-layered protective element (20) for a battery (1) with at least two battery cells (10), which are arranged next to one another, 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) predominantly comprises animal wool and the layer thickness of the core layer is 60 to 98% of the total thickness of the protective element. The invention also relates to a battery (1) and to the use of the protective element (20) for a battery (1).