Battery Pack Insulation Sheet Coating to Prevent Peeling
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Solution Overview
Problem
Existing thermal insulation materials for battery packs face issues such as peeling of polymer coatings due to shrinkage differences, insufficient fire resistance due to high expansion coefficient materials, and increased thermal conductivity, which can lead to thermal runaway and safety concerns in electric vehicles and hybrid vehicles.
Innovation Solution
A thermal insulation sheet with a resin film covering inorganic particles, where the resin film has a thickness of 1 μm to 95 μm, is irregularly curved, and has pores distributed in a dispersed manner, preventing peeling and maintaining low thermal conductivity and flame retardancy, while also containing a combination of inorganic fibers with different properties to enhance mechanical strength and retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polymer coating layer is applied on inorganic thermal insulation material to prevent component falling off, then component retention is improved, but the coating layer may peel off due to shrinkage difference during processing or temperature changes
Solution Approach 1:
The patent applies parameter changes by controlling the thickness of the polymer coating layer to be 1 μm to 95 μm (optimally 5 μm to 50 μm). This specific thickness range balances two competing requirements: sufficient thickness to prevent inorganic particle fallout while being thin enough to minimize shrinkage differential and thermal expansion mismatch between the coating and substrate, thereby preventing peeling during processing and temperature cycling.
2Loss of energy
If graphite with high expansion coefficient is blended in the surface layer to enhance insulation, then thermal insulation is improved, but fire resistance becomes insufficient during thermal runaway
Solution Approach 1:
The patent applies local quality by using inorganic particles (such as alumina, silica, or magnesia) specifically in the polymer coating layer that contacts the battery cell surface, while graphite can be used in the bulk thermal insulation material. This creates a localized fire-resistant barrier at the critical interface where thermal runaway could propagate, while maintaining good thermal insulation properties in the bulk material.
3Stability of the object's composition
If a thick resin layer is applied to prevent peeling, then coating stability is improved, but thermal conductivity increases reducing insulation performance
Solution Approach 1:
The patent applies parameter changes by optimizing the polymer coating layer thickness to a specific range (1 μm to 95 μm, optimally 5 μm to 50 μm). This controlled thickness provides sufficient coverage and stability to prevent peeling and protect inorganic particles, while remaining thin enough to minimize thermal conductivity increase and maintain effective thermal insulation performance.
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 peeling of the resin layer, maintains low thermal conductivity, and ensures flame retardancy, thereby reducing the risk of thermal runaway and enhancing safety in battery packs.
Implementation Method 1
a resin film covering at least a part of a surface of the thermal insulation material
Implementation Method 2
a thermal insulation sheet containing: a thermal insulation material containing inorganic particles
Data Source
AI summary
A thermal insulation sheet containing a thermal insulation material containing inorganic particles and a resin film covering at least a part of a surface of the thermal insulation material. A method for producing the thermal insulation sheet, including: molding a material for a thermal insulation material containing the inorganic particles into a sheet shape; and coating the surface of the thermal insulation material molded into the sheet shape with the resin film forming composition by a screen printing method or a spray coat printing method to form the resin film.