Bio-based Flame Retardant Thermal Interface Material
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Solution Overview
Problem
Lithium-ion batteries face challenges with thermal management and fire risks due to thermal runaway, which can be exacerbated by high temperatures, and existing thermal interface materials often rely on environmentally harmful halogenated flame retardants.
Innovation Solution
A bio-based flame retardant thermal interface material using inexpensive and abundant proteins like wheat gluten, combined with char forming promoters, reinforce agents, foaming agents, and thermal conductive agents, which provides excellent thermal conductivity at normal temperatures and forms an insulating barrier during thermal runaway or fires, made through a process involving microwave foaming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If halogenated flame retardants are used in thermal interface materials, then fire risk is reduced, but environmental harm increases
Solution Approach 1:
The patent changes the chemical composition parameters by replacing halogenated compounds with bio-based proteins (wheat gluten, soy protein, casein, gelatin, collagen) combined with phosphorus-containing flame retardants and metal hydroxides. This substitution maintains flame retardancy while eliminating environmental persistence and toxicity associated with halogenated materials.
Solution Approach 2:
The invention creates a composite material system combining bio-based proteins with phosphorus-containing compounds and metal hydroxides (aluminum trihydroxide, magnesium hydroxide). This composite approach synergistically provides flame retardancy, thermal stability, and environmental compatibility, replacing single-component halogenated flame retardants.
2Temperature
If thermal conductivity is increased at normal operating temperatures, then thermal management improves, but fire risk during thermal runaway may increase
Solution Approach 1:
The patent applies different functional properties to different temperature conditions: at normal operating temperatures (10-40°C), the material provides high thermal conductivity for heat dissipation; at elevated temperatures during thermal runaway, the same material forms an insulating char layer to prevent fire spread. This temperature-dependent dual functionality resolves the contradiction between thermal management and fire safety.
Solution Approach 2:
The material dynamically changes its thermal properties based on temperature: it transitions from a thermally conductive state during normal operation to a thermally insulating charred state during thermal runaway. This dynamic transformation allows the material to optimize performance for different operational conditions.
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 prevents thermal runaway and reduces fire risk by maintaining optimal operating temperatures and forming a protective char layer, while being environmentally friendly and biodegradable.
Implementation Method 1
forms an insulating barrier when the temperature of the battery cell reaches dangerous high level
Implementation Method 2
forms an insulating barrier when the temperature of the battery cell reaches dangerous high level
Implementation Method 3
provides excellent thermal conductivity at normal temperatures
Implementation Method 4
made through a process involving microwave foaming
Implementation Method 5
made through a process involving microwave foaming
Data Source
AI summary
The present invention is directed to a flame retardant thermal interface material. The material contains a bio-based material and associated functional additives, wherein the bio-based material includes a protein and the functional additives include at least one of a char forming promotor, a char reinforce agent, a foaming agent, a thermal conductive agent, a flame suppression agent and other additives. The char forming promotor, the char reinforce agent and the flame suppression agent are used to adjust the combustion behavior of the material to render the material having desired flame retardation performance. The foaming agent and thermal conductive agent are used to adjust thermal conductivity of the material. The present invention is also directed to a process method of making a flame retardation thermal interface material.