Multilayer Insulative Material for Li-Ion Battery Thermal Shielding

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Solution Overview

Problem

Existing insulation materials for lithium-ion batteries fail to provide adequate thermal protection in both extreme heat and cold environments, leading to reduced battery performance and lifespan.

Innovation Solution

A three-layered insulative material comprising a metalized layer to reflect thermal radiation, a low thermal conductivity layer, and a woven or non-woven layer with optional conductive materials for electromagnetic shielding, designed to protect electronic components from temperature extremes and electronic interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If existing insulation materials are used for lithium-ion batteries, then the structure is simple and easy to manufacture, but the thermal protection in extreme heat and cold environments is inadequate

Engineering Contradiction:

Improvethermal protectionVSAvoidmaterial structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent applies composite materials by combining multiple layers with different functions: a metalized layer for thermal radiation reflection, a foam layer for thermal conduction resistance, and a woven/non-woven layer for additional insulation and structural support. This multi-material composite structure achieves superior thermal protection in both extreme heat and cold environments compared to single-material solutions.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The insulation material is segmented into three distinct layers, each designed to address specific thermal protection needs. The metalized layer handles radiant heat, the foam layer provides bulk insulation, and the woven/non-woven layer adds structural integrity and supplementary insulation. This segmentation allows each layer to optimize its function while contributing to overall thermal protection.

Inventive Principle:

Principle #1Segmentation

2Reliability

If a multi-layer insulative material is used to provide thermal protection, then the thermal insulation performance is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvebattery protectionVSAvoidmaterial fabrication

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent employs a nested doll structure where the metalized layer is laminated onto the foam layer, which is in turn surrounded by the woven or non-woven layer. This nested arrangement allows the layers to be manufactured separately and then assembled through lamination processes, maintaining manufacturing feasibility while achieving reliable multi-functional protection.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Object-affected harmful factors

If the metalized layer is used to reflect thermal radiation, then the thermal radiation protection is improved, but the material complexity and layering requirements increase

Engineering Contradiction:

Improvethermal radiationVSAvoidlayer structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent converts the harmful effect of thermal radiation into a beneficial protective mechanism by using the metalized layer to reflect thermal radiation away from the battery. The metalized layer, which would normally conduct heat, is instead configured to reflect radiant heat, transforming a potential heat transfer pathway into a protective barrier against thermal radiation.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 material effectively insulates batteries from extreme temperatures, maintaining performance and extending battery life by reflecting thermal radiation and blocking electromagnetic interference.

Implementation Method 1

the first layer comprises a metalized material capable of reflecting thermal radiation

Methodology Applied

Scientific EffectThermal radiation reflection: Reflection

Implementation Method 2

the second layer comprises a foam, an ultra-low thermally conductive material

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

the second layer comprises a foam, an ultra-low thermally conductive material, a phase change material

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS12565022B2Insulative material

Publication Date: 2026.03.03 EXCLAIM IP LLC

AI summary

A thermally insulating material comprising at least three layers, wherein the first layer comprises a metalized material capable of reflecting thermal radiation, wherein the second layer comprises a foam, an ultra-low thermally conductive material, a phase change material, or a combination thereof, and wherein the third layer (or a fourth layer) comprises a woven or non-woven material and includes at least one conductive material prohibiting transmission of electronic transmissions. In aspects, the metalized layer reflects thermal radiation away from a covered electronic component or device.