Flexible Multi-Layer Battery Insulation for Thermal Runaway

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Solution Overview

Problem

Existing heat insulation solutions for batteries, such as those used in electric vehicles, are brittle, inflexible, and prone to damage during uncontrolled heat events, leading to a loss of thermal insulation function and increased risk of explosion, while also being difficult to install and providing inadequate protection for vehicle occupants.

Innovation Solution

A multi-layer heat insulation element featuring a fibre layer made of long, needled or bonded nonwoven fibres with high mechanical resistance, flexible cover layers, and a woven fabric or mica layer for enhanced mechanical stability and thermal insulation, designed to absorb pressure and delay heat propagation effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing heat insulation solutions are used, then thermal insulation function is provided, but the material is brittle and prone to damage during thermal runaway

Engineering Contradiction:

Improvethermal insulation functionVSAvoidmechanical resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies composite materials by combining organic fibres (cellulose, glass, or synthetic fibres) with inorganic materials (mica, metal foil, or ceramic coatings) to create a heat insulation element that maintains both flexibility and high-temperature resistance. The organic fibres provide mechanical flexibility and structural integrity, while the inorganic materials contribute heat resistance and stability during thermal runaway events.

Inventive Principle:

Principle #40Composite materials

2Reliability

If existing heat insulation solutions are used, then thermal insulation is provided, but the material is inflexible and difficult to install

Engineering Contradiction:

Improvethermal insulation functionVSAvoidinstallation ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent employs flexible shells and thin films by using organic fibre-based materials that can be easily shaped and adapted to fit around battery cells. The fibre structure allows the insulation element to be flexible and conformable, enabling simple installation while maintaining effective thermal insulation performance.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If existing heat insulation solutions are used, then thermal insulation is provided, but the material cannot absorb pressure and delay heat propagation effectively

Engineering Contradiction:

Improveheat protectionVSAvoidpressure absorption

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The patent applies local quality by incorporating specific materials with particular properties at different locations within the composite structure. Mica flakes and metal foil layers are distributed throughout the fibre matrix to provide localized heat reflection and barrier properties, while the fibre structure provides pressure absorption capacity at stress points.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent utilizes phase transitions by incorporating materials that undergo endothermic phase changes at elevated temperatures. The organic fibres and inorganic materials can absorb heat through phase transitions (such as decomposition, melting, or vaporization), thereby delaying heat propagation to adjacent battery cells during thermal runaway.

Inventive Principle:

Principle #36Phase transitions

4Reliability

If existing heat insulation solutions are used, then thermal insulation is provided, but the material may burst and lose insulation function prematurely

Engineering Contradiction:

Improvethermal insulation functionVSAvoidinsulation duration

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The composite structure of organic fibres combined with heat-resistant inorganic materials (mica, metal foil, ceramic coatings) provides both mechanical flexibility and high-temperature stability. This combination prevents the insulation element from bursting during thermal runaway while maintaining insulation function throughout the event duration.

Inventive Principle:

Principle #40Composite materials

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 provides robust, flexible, and efficient thermal insulation that delays the destruction of batteries during thermal runaway, reduces the risk of explosion, and effectively protects vehicle occupants by maintaining a safe temperature and preventing heat transfer to adjacent cells and the vehicle interior.

Implementation Method 1

a needled or bonded nonwoven

Methodology Applied

Scientific EffectMechanical interlocking through needling:

Implementation Method 2

heat insulation element for thermal insulation of a battery

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

a woven fabric or mica layer for enhanced mechanical stability and thermal insulation

Methodology Applied

Scientific EffectThermal radiation blocking: Reflection

Data Source

PatentUS12095066B2Multi-layer thermal insulation element for batteries

Publication Date: 2024.09.17 HKO ISOLIER & TEXTILTECHNIK GMBH

AI summary

A multi-layer heat insulation element for thermal insulation of a battery is proposed, with a first cover layer, with a second cover layer and with a compressible and/or pliable intermediate ply arranged between the cover layers, which has at least one heat-resistant fibre layer, wherein the fibre layer is formed from a needled nonwoven and/or wherein the cover layers are flexurally weak and the heat insulation element as a whole is compressible and flexibly pliable.