Battery Heat-Shielding Sheet With Silicone Foam and Graphite Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heat-shielding sheets for batteries, particularly those using polyurethane foam, exacerbate thermal runaway and fire spread due to poor heat resistance and lack of effective heat dissipation, and require materials that are both flexible and capable of preventing flame and heat transfer.
Innovation Solution
A heat-shielding sheet comprising a silicone foam layer with laminated functional layers, including a flame-retardant layer, a graphite layer, and a barrier layer, which utilizes flame-retardant silicone, ceramic fillers, and graphite to inhibit flame and heat transfer while maintaining flexibility and light weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If polyurethane foam is used in heat-shielding sheets, then the sheet provides basic heat insulation, but the fire spreads and thermal runaway is accelerated when temperature rises rapidly
Solution Approach 1:
The patent uses composite materials by combining silicone foam with multiple functional layers including flame-retardant layer, graphite layer, and barrier layer. This composite structure provides both heat insulation and fire resistance, resolving the contradiction between basic heat insulation and fire safety.
Solution Approach 2:
The patent changes the material parameters by replacing polyurethane foam with silicone foam and incorporating ceramic fillers and flame-retardant additives. These parameter changes transform the material from flammable to flame-retardant while maintaining heat insulation properties.
2Temperature
If aluminum is used as thermally conductive filler mixed in polymer resin, then heat dissipation is improved, but the filler is difficult to be uniformly dispersed and heat transfer path fails to be formed
Solution Approach 1:
The patent replaces the mechanical mixing approach with a surface-modified filler system. The silane coupling agent creates chemical bonds between filler particles and resin, enabling uniform dispersion without relying on mechanical mixing intensity, thus resolving the dispersion uniformity issue.
Solution Approach 2:
The patent changes the surface parameters of the filler particles through silane coupling agent treatment. This surface modification alters the filler's interaction with the resin, improving wetting and dispersion characteristics, and enabling formation of effective heat transfer paths.
3Adaptability or versatility
If interface plate is designed to cope with volume expansion of battery cell, then the battery can accommodate expansion, but the heat-shielding performance and formability are compromised
Solution Approach 1:
The patent creates a multi-functional interface plate that simultaneously provides heat shielding, flame retardancy, and flexibility for volume expansion accommodation. The silicone foam base material provides inherent flexibility while the functional layers provide heat shielding, achieving multiple functions in one component.
Solution Approach 2:
The interface plate uses composite material structure combining flexible silicone foam with functional heat-shielding layers. This composite structure maintains the flexibility needed for volume expansion while adding the heat-shielding performance required for safety.
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 prevents thermal runaway and fire spread by blocking combustion-induced heat transfer and secondary ignition, while providing excellent heat dissipation and mechanical properties, outperforming traditional materials in high-temperature tests.
Implementation Method 1
a flame-retardant layer, a graphite layer, a barrier layer, and the like, in silicone foam
Implementation Method 2
a graphite layer... in silicone foam used in existing heat-shielding sheets for batteries
Implementation Method 3
a barrier layer... rapidly preventing flames and heat from spreading
Data Source
AI summary
Proposed is a heat-shielding sheet for a battery, the sheet sequentially including an inner layer made of a polymer resin, a silicone foam layer, a graphite layer, and a glass bubble layer. Thus, there are advantages of solving the disadvantage of polyurethane foam, used in existing heat-shielding sheets for batteries, that in the event of a fire, the fire spreads and thermal runaway is accelerated, being lighter than metallic materials, and being capable of rapidly preventing flames and heat from spreading.