EV Battery Fire Barrier Coating for Thermal Runaway Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fire barrier materials for electric vehicle batteries face challenges in providing effective thermal insulation and structural integrity while avoiding flammability issues, and combinations of materials often fail to bond well due to flammability constraints.
Innovation Solution
A fire protection coating comprising an inorganic binder and filler, applied to a flame-resistant substrate, which forms a protective ceramic surface under thermal runaway conditions, combining thin flame-resistant materials with a fire protection coating for enhanced thermal insulation and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional fire barrier materials are used, then thermal insulation is provided, but structural integrity and adhesion are insufficient under thermal runaway conditions
Solution Approach 1:
The patent applies composite materials by combining an inorganic binder (such as potassium silicate or sodium silicate) with inorganic fillers (such as kaolin clay, talc, mica, or vermiculite) to create a fire protection coating. This composite formulation provides both thermal insulation properties from the inorganic components and structural integrity through the cohesive bonding of the binder system, resolving the contradiction between insulation and strength under thermal runaway conditions.
2Object-affected harmful factors
If flame resistant materials are used, then flammability is reduced, but adhesion between materials deteriorates
Solution Approach 1:
The patent employs parameter changes by utilizing inorganic binders that undergo chemical transformation at elevated temperatures. The inorganic binder system maintains adhesion properties through chemical bonding mechanisms that are enhanced rather than degraded by thermal exposure, allowing the coating to remain firmly attached to the substrate while providing flame resistance. This resolves the contradiction by changing the binding mechanism from organic to inorganic chemistry.
3Weight of moving object
If thin flame resistant materials are used, then weight is reduced, but protective capability is insufficient
Solution Approach 1:
The patent applies the thin film principle by forming a fire protection coating that provides comprehensive thermal protection in a thin layer configuration. The inorganic binder-based coating system delivers high thermal insulation and structural integrity within a minimal thickness, reducing the overall weight of the battery module while maintaining reliable protective capability against thermal runaway events.
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 coating provides high thermal insulation and structural integrity, preventing heat transfer and protecting against thermal runaway events in electric vehicle batteries, with improved adhesion and blast resistance.
Implementation Method 1
The coating provides high thermal insulation and structural integrity, preventing heat transfer and protecting against thermal runaway events
Data Source
AI summary
A fire protection coating and a fire barrier coated article are provided that comprise an inorganic binder and at least one inorganic filler, wherein the inorganic binder is selected from potassium silicate, sodium silicate, or a combination thereof, and wherein the at least one inorganic filler is selected from kaolin clay, talc, mica, mullite, phlogopite, muscovite montmorillonite, smectite, bentonite, illite, chlorite, sepiolite, attapulgite, halloysite, vermiculite, laponite, rectorite, perlite, and combinations thereof. The fire barrier article comprises flame resistant substrate layer having a first major surface and a second major surface, and a fire protection coating disposed on the first major surface of the flame resistant substrate layer.