Battery Insulation Laminate for Thermal Runaway Flame Containment
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Solution Overview
Problem
Current battery insulation technologies fail to effectively manage thermal runaway in lithium-ion batteries, leading to uncontrolled heat generation, explosions, and the release of toxic gases, posing risks to vehicle occupants and rescue workers.
Innovation Solution
A multilayer protective element comprising a carrier layer of heat-resistant silicate fibers finished with metal oxide and a protective layer of phlogopite, laminated together to provide both thermal and electrical insulation, capable of withstanding extreme temperatures and mechanical loads, thereby delaying or preventing the escape of flames and sparks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional insulation materials are used for battery thermal management, then the battery structure is simple and easy to manufacture, but the materials fail to withstand extreme temperatures during thermal runaway, leading to uncontrolled heat generation and explosions
Solution Approach 1:
The patent applies composite materials by combining silicate fabric (providing structural integrity and heat resistance) with mica layers (providing enhanced thermal insulation and stability). This composite structure achieves superior temperature resistance (withstanding temperatures above 1000°C) while maintaining a relatively simple two-layer configuration that can be manufactured and applied practically.
Solution Approach 2:
The patent implements nesting by placing the silicate fabric as a carrier layer with mica layers integrated onto it. The mica layers are applied in a nested manner on the fabric substrate, creating a hierarchical structure where the fabric provides the base framework and the mica layers provide the functional thermal protection, achieving high temperature resistance without excessive structural complexity.
2Duration of action of stationary object
If thicker insulation layers are used to delay heat release, then thermal protection is improved, but the response time for rescue operations is delayed and space is consumed
Solution Approach 1:
The patent changes the material parameters by using silicate fabric with specific thermal properties and mica layers with high thermal stability. This material selection allows achieving extended protection duration (delaying heat release to surrounding environment) with relatively thin layers, thus not significantly impacting rescue response time or consuming excessive space.
Solution Approach 2:
The patent applies local quality by concentrating the thermal protection function in the mica layers which are specifically positioned on the silicate fabric carrier. This localized functional assignment allows the protective element to achieve effective heat delay with optimized thickness, balancing protection duration with space and time constraints for rescue operations.
3Reliability
If high-performance heat-resistant materials are used, then thermal insulation is improved, but the cost of materials and manufacturing increases
Solution Approach 1:
The patent uses composite materials combining silicate fabric and mica layers, where both components are well-established materials with relatively straightforward manufacturing processes. The silicate fabric provides a familiar textile base, and the mica layers can be applied using conventional coating or lamination techniques, maintaining manufacturing simplicity while achieving high fire protection reliability through the synergistic combination of materials.
Solution Approach 2:
The patent achieves multi-functionality with the silicate fabric carrier that simultaneously provides structural support, heat resistance, and a substrate for mica layer attachment. This universal carrier material eliminates the need for separate structural and functional layers, simplifying manufacturing while ensuring fire protection reliability through the integrated design.
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 insulates and shields against thermal and electrical impacts, reducing the risk of explosions and toxic gas release, providing prolonged protection even at high temperatures, thus ensuring safer vehicle interiors and rescue operations.
Implementation Method 1
The protective element (1) is provided for thermally and/or electrically insulating and/or shielding off a battery (8)... effectively insulates and shields against thermal and electrical impacts
Implementation Method 2
carrier layer of heat-resistant silicate fibers finished with metal oxide... capable of withstanding extreme temperatures and mechanical loads
Data Source
AI summary
A multilayer protective element for thermal and electrical insulation of a battery, a battery having such a protective element, and the use of the protective element for preventing flame or spark leakage from a battery are proposed. The protective element has a carrier layer of a silicate fabric and a protective layer of phlogopite.