Wrapped Thermal Barrier Assembly for Sealed Battery Pack Interfaces
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Solution Overview
Problem
Existing traction battery packs face challenges in effectively mitigating the transfer of thermal energy and establishing a sealed interface with the perimeter environment, which can lead to thermal management issues and reduced performance.
Innovation Solution
A thermal barrier assembly is introduced, comprising a structural barrier and a thermal resistance material wrapping that is wrapped around at least one edge of the structural barrier to seal interfaces with enclosure structures and cross-member assemblies, thereby compartmentalizing the battery cell stack and inhibiting thermal energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thermal barrier assembly is used to mitigate thermal energy transfer, then thermal management performance is improved, but the device complexity increases due to additional components and assembly steps
Solution Approach 1:
The thermal resistance material wrapping is integrated with the structural barrier to form a unified thermal barrier assembly. The wrapping is applied directly around the structural barrier, combining thermal insulation and structural support functions into a single integrated component, thereby reducing overall device complexity while maintaining thermal management performance.
Solution Approach 2:
The thermal barrier assembly serves multiple functions simultaneously: it provides thermal insulation to mitigate heat transfer, maintains structural integrity of the battery pack, and establishes sealed interfaces with perimeter structures. This multi-functionality reduces the need for separate components, thereby improving thermal management without proportionally increasing device complexity.
2Reliability
If thermal resistance material wrapping is applied to seal interfaces, then sealing performance is improved, but manufacturing complexity increases due to additional wrapping steps
Solution Approach 1:
The thermal resistance material wrapping is applied to the structural barrier in advance, before the thermal barrier assembly is installed into the battery pack. This preliminary preparation allows the wrapping to be pre-positioned and pre-sealed, simplifying the final assembly process and reducing manufacturing complexity while ensuring reliable sealed interfaces are established when the assembly is installed.
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 thermal barrier assembly effectively reduces thermal energy transfer within the traction battery pack, while establishing a sealed interface with the perimeter environment, thereby enhancing thermal management and maintaining performance.
Implementation Method 1
a thermal resistance material wrapping that is wrapped around at least one edge of the structural barrier to seal interfaces with enclosure structures and cross-member assemblies, thereby compartmentalizing the battery cell stack and inhibiting thermal energy transfer
Data Source
AI summary
Thermal barrier assemblies are configured for inhibiting the transfer of thermal energy inside a traction battery pack. The thermal barrier assemblies may be further configured for establishing a sealed interface between the thermal barrier assembly and one or more perimeter environments. An exemplary thermal barrier assembly may include a structural barrier, and a thermal resistance material wrapping that is wrapped around at least one edge of the structural barrier.