Multi-functional, multi-layer hybrid composite structure

Abstract

A multi-layer and multi-functional composite structure is provided that includes a structural reinforcement portion configured to provide structural support. The structural reinforcing portion includes reinforcing fibers consolidated in a thermoplastic resin. The protection portion is disposed on one side of the structural reinforcement portion and is configured to provide at least one of thermal barrier and fire resistance. The shielding portion is disposed on an opposite side of the structural reinforcement portion and is configured to shield electromagnetic interference (EMI).

Description

Technical Field

[0001] The present disclosure relates to multifunctional and multi-layered hybrid composite structures. Background Art

[0002] The information provided in this section is intended to generally introduce the background of the present disclosure. To the extent that work currently named as inventors is described in this section, and aspects of the specification that may not have been otherwise identified as prior art at the time of filing, are not admitted, either explicitly or implicitly, as prior art to the present disclosure.

[0003] The present disclosure relates to multifunctional and multi-layered hybrid composite structures.

[0004] Vehicles include structural components, such as housings or other structures that are typically made of metal (e.g., steel or aluminum). In addition to providing structural support functions, structural components may also need to perform other functions, such as thermal insulation, fire protection, and / or electromagnetic shielding. For example, structural components can be used when manufacturing housings for battery packs or electric motors. When structural components are made of aluminum or steel, the structural components may be relatively heavy. Summary of the invention

[0005] The multilayer and multifunctional composite structure includes a structural reinforcement portion configured to provide structural support. The structural reinforcement portion includes reinforcing fibers consolidated in a thermoplastic resin. The thermoplastic resin can be pre-impregnated into the reinforcing fibers and / or supplied during a compression molding process. The protective portion is arranged on one side of the structural reinforcement portion and is configured to provide at least one of thermal insulation and fire resistance. The shielding portion is arranged on the opposite side of the structural reinforcement portion and is configured to shield electromagnetic interference (EMI).

[0006] In other features, the structural reinforcement portion and at least one of the protective portion and the shielding portion are consolidated in a thermoplastic resin in a single step. The structural reinforcement portion, the protective portion, and the shielding portion are consolidated in a thermoplastic resin in a single step. The protective portion includes an expanded material.

[0007] In other features, the intumescent material includes an adhesive layer configured to attach the intumescent material to the structural reinforcement portion. The protective portion includes a mica board attached to the protective portion using an adhesive. The protective portion includes a fabric, a thermal material, and a fireproof material. The protective portion includes a ceramic layer.

[0008] In other features, at least one of the protective portion and the shielding portion includes a coating. The shielding portion is selected from a metal mesh, a discontinuous fabric, a coated yarn, a metal sheet, a perforated metal sheet, and a metal-coated fiber filling material. The structural reinforcement portion includes discontinuous fibers selected from short-cut fibers, unidirectional tapes, non-woven mats, and oriented long fibers. The thermoplastic resin is selected from polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, and polyetherimide.

[0009] In other features, the planar portion of the structural reinforcement portion includes continuous fibers and the non-planar portion of the structural reinforcement portion includes discontinuous fibers.

[0010] A multi-layer and multifunctional composite structure includes a structural reinforcement portion configured to provide structural support and including reinforcing fibers consolidated in a thermoplastic resin. A protective portion is disposed on one side of the structural reinforcement portion and is configured to provide at least one of thermal insulation and fire resistance. A shielding portion is disposed on an opposite side of the structural reinforcement portion and is configured to shield electromagnetic interference (EMI). The structural reinforcement portion and at least one of the protective portion and the shielding portion are consolidated in the thermoplastic resin in a single step.

[0011] In other features, the structural reinforcement portion, the protective portion and the shielding portion are consolidated in a thermoplastic resin in a single step. The protective portion is selected from an expanded material consolidated in a thermoplastic resin and attached to the structural reinforcement portion, a mica board attached to the protective portion using an adhesive, a ceramic layer and a coating. The protective portion includes a fabric, a thermal material and a fireproof material. The shielding portion is selected from a metal mesh, a discontinuous fabric, a coated yarn, a metal sheet and a metal-coated fiberfilled material.

[0012] In other features, the structural reinforcement portion includes discontinuous fibers selected from chopped fibers, unidirectional tapes, nonwoven mats, and oriented long fibers. The thermoplastic resin is selected from polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, and polyetherimide. The planar portion of the structural reinforcement portion includes continuous fibers, and the non-planar portion of the structural reinforcement portion includes discontinuous fibers.

[0013] The present invention provides the following solutions:

[0014] Solution 1. A multi-layer and multifunctional composite material structure comprising:

[0015] a structural reinforcement portion configured to provide structural support and comprising reinforcing fibers consolidated in a thermoplastic resin;

[0016] a protective portion disposed on one side of the structural reinforcement portion and configured to provide at least one of thermal insulation and fire protection; and

[0017] A shielding portion is disposed on an opposite side of the structural reinforcement portion and is configured to shield electromagnetic interference (EMI).

[0018] Option 2. A multilayer and multifunctional composite material structure according to Option 1, wherein the structural reinforcement portion and at least one of the protection portion and the shielding portion are consolidated in the thermoplastic resin in a single step.

[0019] Option 3. A multilayer and multifunctional composite material structure according to Option 1, wherein the structural reinforcement part, the protective part and the shielding part are consolidated in the thermoplastic resin in a single step.

[0020] Option 4. A multilayer and multifunctional composite material structure according to Option 1, wherein the protective portion comprises an expanded material.

[0021] Option 5. A multilayer and multifunctional composite structure according to Option 4, wherein the expansion material includes an adhesive layer configured to attach the expansion material to the structural reinforcement portion.

[0022] Option 6. A multilayer and multifunctional composite material structure according to Option 1, wherein the protective portion includes a mica board attached to the protective portion using an adhesive.

[0023] Option 7. A multilayer and multifunctional composite structure according to Option 1, wherein the protective part includes fabric, thermal material and fire-proof material.

[0024] Option 8. A multilayer and multifunctional composite material structure according to Option 1, wherein the protective portion comprises a ceramic layer.

[0025] Option 9. A multilayer and multifunctional composite material structure according to Option 1, wherein at least one of the protective portion and the shielding portion comprises a coating.

[0026] Option 10. A multilayer and multifunctional composite material structure according to Option 1, wherein the shielding part is selected from metal mesh, discontinuous fabric, coated yarn, metal sheet, perforated metal sheet and metal-coated fiber filling material.

[0027] Option 11. A multilayer and multifunctional composite structure according to Option 1, wherein the structural reinforcement portion comprises discontinuous fibers selected from chopped fibers, unidirectional tapes, non-woven mats and oriented long fibers.

[0028] Option 12. A multilayer and multifunctional composite material structure according to Option 1, wherein the thermoplastic resin is selected from polyetheretherketone, polyetherketoneketone, polyphenylene sulfide and polyetherimide.

[0029] Option 13. A multilayer and multifunctional composite structure according to Option 1, wherein the planar portion of the structural reinforcement portion comprises continuous fibers and the non-planar portion of the structural reinforcement portion comprises discontinuous fibers.

[0030] Scheme 14. A multi-layer and multifunctional composite material structure comprising:

[0031] a structural reinforcement portion configured to provide structural support and comprising reinforcing fibers consolidated in a thermoplastic resin;

[0032] a protective portion disposed on one side of the structural reinforcement portion and configured to provide at least one of thermal insulation and fire protection; and

[0033] a shielding portion disposed on an opposite side of the structural reinforcement portion and configured to shield electromagnetic interference (EMI),

[0034] wherein the structural reinforcement portion and at least one of the protection portion and the shielding portion are consolidated in the thermoplastic resin in a single step.

[0035] Option 15. A multilayer and multifunctional composite material structure according to Option 14, wherein the structural reinforcement part, the protective part and the shielding part are consolidated in the thermoplastic resin in a single step.

[0036] Option 16. A multilayer and multifunctional composite structure according to Option 14, wherein the protective part is selected from: an expansion material solidified in the thermoplastic resin and attached to one of the structural reinforcement parts, a mica board attached to the protective part using an adhesive, a ceramic layer and a coating.

[0037] Option 17. A multilayer and multifunctional composite structure according to Option 14, wherein the protective part includes fabric, thermal material and fireproof material.

[0038] Option 18. A multilayer and multifunctional composite structure according to Option 14, wherein the shielding part is selected from metal mesh, discontinuous fabric, coated yarn, metal sheet and metal-coated fiber filling material.

[0039] Option 19. A multilayer and multifunctional composite material structure according to Option 14, wherein:

[0040] The structural reinforcement portion comprises discontinuous fibers selected from the group consisting of chopped fibers, unidirectional tapes, nonwoven mats, and oriented long fibers, and

[0041] The thermoplastic resin is selected from polyetheretherketone, polyetherketoneketone, polyphenylene sulfide and polyetherimide.

[0042] Option 20. A multilayer and multifunctional composite structure according to Option 14, wherein the planar portion of the structural reinforcement portion comprises continuous fibers and the non-planar portion of the structural reinforcement portion comprises discontinuous fibers.

[0043] Further areas of applicability of the present disclosure will become apparent from the detailed description, claims and drawings.The detailed description and specific examples are intended to be illustrative only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The present disclosure will be more fully understood through the detailed description and accompanying drawings, in which:

[0045] Figure 1A is a functional block diagram of an example of a battery cell including an anode electrode, a cathode electrode, and a separator;

[0046] Figure 1B is a functional block diagram of an example of a battery pack housing made of a multifunctional and multi-layered thermal composite structure according to the present disclosure;

[0047] Figure 1C is a functional block diagram of an example of an electric machine arranged in a housing made of a multifunctional and multi-layered thermal composite structure according to the present disclosure;

[0048] FIG. 2A to FIG. 2C is a cross-sectional view of an example of a multifunctional and multilayered thermal composite structure of the present disclosure; and

[0049] Figures 3 to 5 is a flow chart of an example of a method of making a multi-layered and multifunctional hybrid composite structure according to the present disclosure.

[0050] Among the drawings, reference numerals may be repeated to identify similar and / or identical elements. DETAILED DESCRIPTION

[0051] Although the multi-layer and multifunctional hybrid composite structure is described below in the context of a structural component or shell of a vehicle, the multi-layer and multifunctional hybrid composite structure may be used in other applications.

[0052] The present disclosure relates to a multi-layer and multifunctional hybrid composite structure ("hybrid composite structure") that provides high strength, reduced heat transfer and / or electromagnetic interference (EMI) shielding. For example, the hybrid composite structure can be used to manufacture a housing for a battery pack, motor, or other device to reduce heat transfer and / or EMI to / from the surrounding environment. For example, the hybrid composite structure can be used to prevent thermal runaway propagation (TRP) from one battery cell, module, and / or battery pack to an adjacent battery cell, module, and / or battery pack. Housings or other structures manufactured using the hybrid composite structure have reduced components and lower mass (e.g., a 40% or more mass reduction compared to a housing or other structure made of metal).

[0053] The hybrid composite structure includes multiple parts or layers that support different functions and / or include various materials (e.g., EMI shielding materials, thermal insulation materials, flame retardant materials, reinforcing fibers and / or resins). In some examples, the hybrid composite structure is consolidated in a single process step, such as compression molding using a thermoplastic resin. In other examples, the hybrid composite structure is consolidated in one or more process steps.

[0054] In some examples, surface pretreatment methods can be applied to enhance the adhesion between functional layers (e.g., EMI shielding layers, thermal insulation layers, and / or fire protection layers) and other layers of the hybrid composite structure. Examples of surface pretreatment include exposing the material or adjacent surfaces to plasma or flame to heat the surface to improve adhesion to adjacent layers of the hybrid composite structure.

[0055] In some examples, the inner portion of the hybrid composite structure includes a thermal insulation layer and / or a flame retardant layer embedded in the resin. The middle portion of the hybrid composite structure includes reinforcing fibers embedded in the resin. The outer portion of the hybrid composite structure includes an EMI shielding layer embedded in the resin. The outer portion faces the external environment. In some examples, the hybrid composite structure is made using a thermoplastic resin. Thermoplastic resins have greater recovery and recycling potential than thermosetting resins.

[0056] The versatility of the hybrid composite structure is that it can provide strength and stiffness, TRP protection and / or EMI shielding. In some examples, the reinforcing fibers include discontinuous fibers, continuous fibers, and / or combinations thereof in different regions of the hybrid composite structure to adjust the strength and stiffness where needed.

[0057] Reference now Figures 1A to 1C , showing various examples of enclosures comprising hybrid composite structures. Figure 1A In FIG. 1 , an example of a battery cell is shown. Figure 1B In the embodiment, the housing for a battery pack including a hybrid composite material structure includes a plurality of battery modules (each battery module includes a housing and a plurality of Figure 1A battery pack). Figure 1C In the embodiment, the motor is arranged in a housing including a hybrid composite structure. The housing for the battery module, battery pack and / or motor may include a body and / or a cover that provides an airtight seal. The body and / or cover may be manufactured using the hybrid composite structure described further below.

[0058] For example, a thermal runaway event may occur when a battery cell in one or more battery modules or battery packs fails. A thermal runaway event is caused when the temperature of a battery cell, battery module, and / or battery pack increases. The increased temperature releases energy from the battery cell, which further increases the temperature of the battery pack and / or adjacent structures. If not extinguished, the battery cells, battery modules, and / or battery packs will experience a thermal runaway event, which may cause the temperature of other adjacent battery modules / battery packs to increase. The increase in temperature increases the likelihood of further thermal runaway events (thermal runaway propagation (TRP)).

[0059] Reference now Figure 1A , the battery cell 10 includes C cathode electrodes 20, A anode electrodes 40, and S separators 32 arranged in a predetermined order in a stack 12 arranged in a battery cell housing 50. The cathode electrodes 20-1, 20-2, ..., and 20-C (where C is an integer greater than 1) include a cathode active layer 24 arranged on one side or both sides of a cathode current collector 26. The anode electrodes 40-1, 40-2, ..., and 40-A (where A is an integer greater than 1) include an anode active layer 42 arranged on one side or both sides of an anode current collector 46.

[0060] In some instances, the anode active layer 42 and / or the cathode active layer 24 include a coating including one or more active materials, one or more conductive fillers / additives, and / or one or more adhesive materials. In some instances, the battery cells and / or electrodes are manufactured by applying a slurry to coat the current collector in a roll-to-roll manufacturing process. In some instances, the cathode current collector 26 and the anode current collector 46 include a foil layer. In some instances, the current collector is made of one or more materials selected from copper, stainless steel, brass, bronze, zinc, aluminum, and alloys thereof. External tabs 28 and 48 enable external connection to the current collector and can be arranged on the same side, opposite sides, or different sides.

[0061] exist Figure 1B , the battery pack 90 includes a battery pack housing 92 surrounding a plurality of battery modules 80-1, 80-2, ..., and 80-M, where M is an integer greater than 1. The battery pack housing 92 includes a cover 93 and a lower body or tray 95. Each battery module 80 includes a battery module housing 82 and a plurality of battery cell housings 50-1, 50-2, ..., 50-C arranged in the battery module housing 82. In some examples, the battery module housing 82 and / or the battery pack housing 92 are made using a hybrid composite structure.

[0062] exist Figure 1CIn the embodiment, the motor 96 is arranged in a housing 98. In some examples, the housing 98 for the motor 96 is made using a hybrid composite material structure. In some examples, the housing 98 may include a cover 97 and a body 99.

[0063] Reference now FIG. 2A to FIG. 2C , showing an example of a hybrid composite structure. Figure 2A In the embodiment of the present invention, the multilayer hybrid composite structure 150 includes an inner surface 152 facing the device (e.g., battery pack, motor, etc.) and an outer surface 154. The hybrid composite structure 150 includes a thermal protection portion 160 configured to provide thermal insulation and / or fire resistance, a structural reinforcement portion 164 configured to provide structural support for the housing, and a shielding portion 168 configured to shield EMI.

[0064] In some examples, the reinforcement portion 164 is consolidated and then the thermal protection portion 160 and the shielding portion 168 are attached using an adhesive and / or using a surface pretreatment step such as using plasma or flame heating. In some examples, the thermal protection portion 160 and the reinforcement portion 164 are consolidated in the same consolidation step. In some examples, the reinforcement portion 164 and the shielding portion 168 are consolidated in the same consolidation step. In some examples, the thermal protection portion 160, the reinforcement portion 164, and the shielding portion 168 are consolidated in the same consolidation step. In other examples, the reinforcement portion 164 is pre-consolidated and one or more additional consolidation steps are performed.

[0065] The heat protection part 160 comprises one or more layers 180 embedded in the resin 184. Thermoplastic resin can be pre-impregnated into the reinforcing fiber and / or supplied in the compression molding process. In some instances, one or more layers 180 of the heat protection part 160 include expansion materials. The example of flame retardant (fire retardant) material includes fabrics impregnated with flame retardants such as tetrahydrate aluminum (ATH) and / or ammonium polyphosphate (APP). Additional examples of flame retardant materials include kaolin, sodium silicate, aluminum hydroxide, magnesium hydroxide, hydrated silicon dioxide, silicone, titanium dioxide and compounds based on phosphorus, nitrogen, antimony, boron, zinc or halogens such as bromine and chlorine. The combination of these materials can also be used. In some instances, the protection part 160 includes a ceramic material embedded in the resin. In some instances, the protection part 160 includes a rigid plate made of mica.

[0066] The example of expansion material includes expanded graphite (EG). Additional examples of expansion material include a combination of materials for producing insulating carbon, including an acid source, a carbon source and a foaming agent. The acid source helps to trigger an expansion reaction, and may include phosphates that release phosphoric acid when heated, such as ammonium polyphosphate, melamine phosphate and guanyl urea phosphate, which may also serve as a carbon source. Compounds and acidic polymers that release other acids such as boric acid may also be used as acid sources. The carbon source provides a carbonaceous carbon layer and may include expandable graphite, polyols (such as pentaerythritol and sorbitol) and carbohydrates (such as starch, cellulose and dextrin). The foaming agent releases gas when heated, causing the expansion material to form an expanded carbon layer, and may include ammonium polyphosphate, melamine, ammonium bicarbonate, sodium bicarbonate, urea and azodicarbonamide. When heated to above a predetermined temperature, the expansion material expands and forms a protective carbon to serve as a fire barrier. In some instances, the predetermined temperature corresponds to the temperature encountered during a thermal runaway event.

[0067] In some examples, one or more layers 180 include a flexible fabric reinforced with a thermal material and / or a flame retardant layer. In some examples, the thermal material and / or the flame retardant layer undergoes minimal or no expansion when exposed to high heat or flame. Examples include materials that undergo pyrolysis and form a carbonaceous char or an insulating layer. Examples include cement-based materials, clay, calcium silicate, silicon dioxide, aluminum oxide, zirconium oxide, gypsum, and ceramics.

[0068] In some examples, the thermal protection portion 160 includes a material that undergoes an endothermic reaction to absorb heat. Examples of these materials include ammonium phosphate, hydrated compounds such as aluminum and magnesium hydrates, ammonium sulfate, melamine cyanurate, some phosphorus compounds, potassium carbonate. In some examples, the thermal protection portion 160 maintains electrical insulation properties during exposure to flames. Examples of these materials include silicone compounds, phenolic resins, mineral compounds, and ceramics.

[0069] In some examples, the reinforcement layer 164 includes reinforcement fibers 186, including continuous fibers, discontinuous fibers and / or a mixture of continuous fibers and discontinuous fibers. Suitable reinforcement fibers include carbon fibers (e.g., carbon black, carbon nanotubes, talc, fibers derived from polyacrylonitrile, cellulose precursors and / or asphalt precursors), glass fibers (e.g., glass fibers, quartz), basalt fibers, aramid fibers, and combinations thereof. In some examples, the continuous fibers are arranged in a planar portion of the structure and / or the discontinuous fibers are arranged in a non-planar or irregular portion of the structure.

[0070] In some examples, the EMI shielding layer 188 comprises a woven metal mesh, a continuous or discontinuous flexible fabric, a coated yarn, a metal sheet, a perforated metal sheet, or a metal-coated fiber filler material. By way of example only, the EMI shielding layer may comprise aluminum foil, a copper mesh, a nickel mesh, copper and nickel electrolytically coated carbon fibers.

[0071] exist Figure 2B In the embodiment of the present invention, the reinforcing portion 164 is consolidated, and then the thermal protection portion 160 is attached using adhesive (and / or surface treatment) or consolidated in a second consolidation step. The shielding portion 168 is also attached using adhesive (and / or surface treatment) or consolidated on the other side of the reinforcing portion 164 in a second or subsequent consolidation step.

[0072] For example, one or more layers 192 of the thermal protection portion 160 are attached to one side of the reinforcement portion 164 by an adhesive layer 193. In some examples, one or more layers 192 include a thermal insulation layer and / or a flame retardant layer. In some examples, the reinforcement layer 164 includes reinforcement fibers 186. In some examples, the reinforcement fibers 186 include continuous fibers, discontinuous fibers, and / or a mixture of continuous fibers and discontinuous fibers. The shielding layer 168 includes an electromagnetic interference (EMI) shielding layer 193 attached to the reinforcement portion 164 by an adhesive 194 (and / or surface treatment).

[0073] exist Figure 2C In the embodiment of the present invention, the thermal protection portion 160 includes a protective coating 196 applied to the exposed surface of the reinforcement portion 164. In some examples, the protective coating 196 is applied in liquid form using spraying, dipping, flow coating, and / or other suitable coating methods. In some examples, the coating includes flame retardant compounds, such as those described previously as flame retardants, intumescent materials, hydrating materials, and ceramics, as well as adhesives, solvents, and other additives used in the coating. In some examples, when the reactants are combined, heat, UV exposure, moisture, and / or a chemical reaction at room temperature (or another temperature) are used to cure the protective coating 196.

[0074] In some examples, the EMI shielding layer 188 includes a coating 198 that is applied in liquid form and optionally cured as described above. In some examples, the EMI shielding layer includes a coating that includes conductive particles (e.g., copper, aluminum, silver, nickel, gold, tin, or graphene). In other examples, the shielding layer is applied using a metal plating process.

[0075] In some examples, the hybrid composite structure was able to withstand a 950°C flame for 5 minutes while limiting the temperature on the opposite side of the hybrid composite structure to a temperature below 370°C.

[0076] In some examples, the hybrid composite structure includes discontinuous carbon fibers in a thermoplastic polymer matrix. In some examples, the discontinuous carbon fibers include unidirectional tapes, nonwoven mats, and / or oriented long fibers, and the technology is used together with compression molding or stamping. In some examples, the hybrid composite structure includes chopped carbon fiber fillers and a polymer matrix, the polymer matrix including a thermoplastic polymer selected from polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyphenylene sulfide (PPS), polyetherimide (PEI), and combinations thereof.

[0077] In some examples, the hybrid composite structure includes continuous fibers in planar regions and discontinuous fibers in regions of non-planar geometric features, such as channels, ribs, reinforcements, and / or hat-shaped portions. In some examples, the hybrid composite structure is produced in a single consolidation step using a compression molding process.

[0078] Reference now Figures 3 to 5 , examples of methods 250, 300, and 400 for manufacturing a hybrid composite structure and / or a housing including a hybrid composite structure are shown. Figure 3 In the method 250, at 260, the protective layer(s), reinforcing fibers, and shielding layers are arranged in a stack. At 264, the stack is impregnated with a resin (e.g., a thermoplastic resin) and consolidated into a multi-layer and multifunctional hybrid composite structure using pressure and / or heat in a single step. At 268, the multi-layer hybrid composite structure is used to manufacture a housing or other structure.

[0079] exist Figure 4 In the method 300, at 310, reinforcing fibers are arranged in a pattern. At 314, the reinforcing fibers are impregnated with a resin (e.g., a thermoplastic resin) and consolidated using pressure and / or heat to form a reinforcement portion. At 318, a heat / fire portion and an EMI shielding portion are attached to or consolidated on opposite sides of the reinforcement portion to produce a multi-layer and multifunctional hybrid composite structure. At 322, the multi-layer hybrid composite structure is used to manufacture a housing or other structure.

[0080] exist Figure 5 In the method 400, at 410, reinforcing fibers are arranged in a pattern. At 414, reinforcing resin and at least one of the heat / fire portion or the shielding portion are impregnated with a resin (e.g., a thermoplastic resin) and consolidated using pressure and / or heat to form a consolidated core. At 418, the other of the heat / fire portion and the EMI shielding portion are attached or consolidated to the consolidated core to produce a multi-layer and multifunctional hybrid composite structure. At 422, the multi-layer hybrid composite structure is used to manufacture a housing or other structure.

[0081] The foregoing description is essentially only exemplary and is absolutely not intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in various forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be limited thereto, because after studying the drawings, the specification and the following claims, other modifications will become apparent. It should be understood that one or more steps in the method may be implemented in different orders (or simultaneously) without changing the principles of the present disclosure. In addition, although each embodiment is described above as having certain features, any one or more features described with respect to any embodiment of the present disclosure may be implemented in any other embodiment and / or combined with the features of any other embodiment, even if the combination is not explicitly described. In other words, the embodiments are not mutually exclusive, and the mutual replacement of one or more embodiments is still within the scope of the present disclosure.

[0082] Various terms are used to describe the spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.), including "connected," "engaged," "coupled," "adjacent," "next to," "on top of," "on," "under," and "disposed." Unless explicitly described as "directly," when describing the relationship between a first element and a second element in the above disclosure, the relationship can be a direct relationship in which no other intervening elements exist between the first element and the second element, or an indirect relationship in which one or more intervening elements exist between the first element and the second element (spatially or functionally). The phrase "at least one of A, B, and C" as used herein should be interpreted to mean a logical (A or B or C) using a non-exclusive logical OR, and should not be interpreted to mean "at least one A, at least one B, and at least one C."

[0083] In the drawings, the direction of the arrows, as shown by arrows, generally demonstrates the flow of information (such as data or instructions) related to the diagram. For example, when component A and component B exchange various information but the information transmitted from component A to component B is related to the diagram, the arrow may point from component A to component B. Such a unidirectional arrow does not mean that no other information is transmitted from component B to component A. In addition, for the information transmitted from component A to component B, component B may send a request for the information to component A or a receipt of the information.

Claims

1. A multi-layer and multifunctional composite material structure comprising: a structural reinforcement portion configured to provide structural support and comprising reinforcing fibers consolidated in a thermoplastic resin; a protective portion disposed on one side of the structural reinforcement portion and configured to provide at least one of thermal insulation and fire protection; and A shielding portion is disposed on an opposite side of the structural reinforcement portion and is configured to shield electromagnetic interference (EMI).

2. The multilayer and multifunctional composite material structure according to claim 1, wherein the structural reinforcement portion and at least one of the protection portion and the shielding portion are consolidated in the thermoplastic resin in a single step.

3. The multilayer and multifunctional composite material structure according to claim 1, wherein said structural reinforcement portion, said protection portion and said shielding portion are consolidated in said thermoplastic resin in a single step.

4. The multilayer and multifunctional composite material structure according to claim 1, wherein the protective portion comprises an expanded material.

5. The multilayer and multifunctional composite structure according to claim 4, wherein the intumescent material comprises an adhesive layer configured to attach the intumescent material to the structural reinforcement portion.

6. The multilayer and multifunctional composite material structure according to claim 1, wherein the protective portion comprises a mica sheet attached to the protective portion using an adhesive.

7. The multilayer and multifunctional composite material structure according to claim 1, wherein the protective portion comprises fabric, thermal material and fireproof material.

8. The multilayer and multifunctional composite material structure according to claim 1, wherein the protective portion comprises a ceramic layer.

9. The multilayer and multifunctional composite material structure according to claim 1, wherein at least one of the protection portion and the shielding portion comprises a coating.

10. The multilayer and multifunctional composite structure according to claim 1, wherein the shielding portion is selected from the group consisting of metal mesh, discontinuous fabric, coated yarn, metal sheet, perforated metal sheet and metal coated fiber fill material.

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