Ceramic Fiber and Polyurethane Foam Composite for Battery Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heat-resistant components face challenges such as brittleness, high cost, difficulty in shaping, and inadequate electrical insulation, particularly when exposed to high temperatures and mechanical stress, as seen in current fireproof panels and insulation components for vehicles and batteries.
Innovation Solution
A layering structure featuring ceramic fiber paper on the inside and partially penetrating polyurethane rigid foam on the outside, with a transition zone between the two, ensuring mechanical and thermal resistance, electrical insulation, and ease of shaping, while using a method that allows for reinforcement and adjustable depth of foam penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If glass-impregnated graphite fabric is used for fire resistance, then heat resistance is improved, but cost increases and brittleness worsens
Solution Approach 1:
The patent uses a composite structure combining ceramic fiber paper (for heat resistance) with polyurethane foam (for flexibility and strength). This composite approach allows the component to withstand temperatures up to 1500°C while maintaining mechanical flexibility and tear resistance, avoiding the brittleness of graphite fabric.
2Temperature
If glass-impregnated graphite fabric is used, then fire resistance is improved, but ease of shaping worsens
Solution Approach 1:
The patent changes the material parameters by using polyurethane foam instead of graphite fabric. The foam can be easily molded into three-dimensional shapes before curing, while the ceramic fiber paper layer maintains fire resistance. This allows complex geometries to be manufactured without the shaping difficulties associated with graphite materials.
3Strength
If bonding layers are used to join ceramic fiber paper and foam, then structural integrity is improved, but detachment under heat worsens
Solution Approach 1:
The patent merges the bonding function into the foam structure itself. The polyurethane foam is applied in liquid form, penetrates the ceramic fiber paper, and then cures to form a monolithic structure where the foam and paper are permanently bonded. This eliminates separate bonding layers that would detach under heat, creating a unified composite material.
4Strength
If aluminum mesh sheath is used for protection, then mechanical strength is improved, but heat resistance worsens
Solution Approach 1:
The patent eliminates the aluminum mesh sheath entirely, relying instead on the inherent strength and thermal stability of the ceramic fiber foam composite. The ceramic fiber paper and cured polyurethane foam provide sufficient mechanical protection without the melting point limitation of aluminum (660°C), allowing the component to withstand temperatures up to 1500°C.
5Loss of energy
If ceramic fiber paper density is increased to 250-500 kg/m3 for better insulation, then thermal insulation is improved, but manufacturing complexity worsens
Solution Approach 1:
The patent changes the density parameter of the ceramic fiber paper to 250-500 kg/m3, which provides optimal thermal insulation while maintaining ease of handling. The liquid polyurethane foam is applied to this density range, and during curing, the foam expansion and penetration naturally compress the paper to the desired density without requiring separate compression steps, simplifying manufacturing.
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 a lightweight, dimensionally stable, tear-resistant, and highly insulating component that maintains electrical insulation and structural integrity under high temperatures, making it suitable for battery panels and partitions.
Implementation Method 1
a rigid polyurethane foam that only partially penetrates the ceramic fiber paper, creating a transition zone between the ceramic fiber paper and the rigid foam
Implementation Method 2
In this way, the two layers are permanently bonded and resistant to mechanical and thermal influences
Implementation Method 3
highly heat-insulating... the rigid foam layer alone is insufficient to provide the required strength
Implementation Method 4
It is also an electrical insulator, thus preventing short circuits in the event of a fire
Implementation Method 5
The layer is produced in situ by applying the liquid components polyol and isocyanate to the ceramic fiber paper
Implementation Method 6
this density is increased to the desired level by compression—either mechanically or by expanding rigid foam
Data Source
Figure 1
Figure 2
Figure 4~5
AI summary
The heat-resistant component consists of bonded layers, one of which is rigid foam and the other ceramic fiber paper. To achieve high dimensional stability, tear resistance, thermal insulation, fire resistance, and electrical insulation, the ceramic fiber paper layer (1) is located on the hot inner surface of the component, followed on the outer surface by the rigid foam layer (2), which penetrates the ceramic fiber paper layer (1) to a certain extent, creating a transition zone (3) of fiber paper and rigid foam. Components manufactured using this method are particularly suitable for cladding and for partitions in electrical accumulators.