Ceramic Fire-Barrier Coating for Battery Thermal Runaway
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Solution Overview
Problem
Current materials fail to effectively protect against high-temperature fires and shrapnel ejection during thermal runaway events in electric vehicle battery modules, as they either cannot withstand extreme temperatures or are compromised by particle blasts, and must also endure various environmental stresses like humidity and vibration.
Innovation Solution
A coating composition comprising an inorganic filler, an inorganic binder, and chopped organic fibers, which forms a protective ceramic surface capable of withstanding temperatures over 750°C and particle ejection, applied to substrates like flame-resistant paper or boards to create a fire barrier that provides thermal insulation and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional fire-resistant materials are used to withstand high temperatures, then thermal resistance is improved, but they cannot withstand the blast and particle ejection from thermal runaway events
Solution Approach 1:
The patent applies composite materials by combining inorganic binder (5-50 wt%), inorganic filler (20-70 wt%), and organic fiber (5-30 wt%) to create a coating that simultaneously provides thermal resistance and blast resistance. The inorganic components provide heat resistance while the organic fiber reinforcement provides structural integrity against particle blasts, resolving the contradiction between thermal protection and mechanical durability.
2Weight of stationary object
If the coating is made thin and lightweight, then ease of application and cost are improved, but protective capability against extreme temperatures and blasts is reduced
Solution Approach 1:
The patent employs thin film technology by formulating a coating composition that achieves effective fire barrier performance in a thin, lightweight layer. The optimized composition with specific ratios of inorganic binder, filler, and organic fiber creates a dense, protective film that provides adequate protection against high temperatures and particle ejection without requiring thick applications, thus maintaining lightweight properties while ensuring reliability.
3Use of energy by moving object
If high energy density batteries are used to increase vehicle range, then energy capacity is improved, but risk of catastrophic thermal runaway and shrapnel ejection is increased
Solution Approach 1:
The patent applies beforehand cushioning by providing a pre-applied protective coating on battery enclosure surfaces before thermal runaway occurs. This coating acts as a protective barrier that cushions against the harmful effects of particle ejection and extreme heat during thermal runaway events, allowing high energy density batteries to be used while mitigating the severity of potential catastrophic failures.
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 coating composition effectively prevents fire penetration and shrapnel damage during thermal runaway events, maintaining integrity and insulation even under extreme conditions, thus ensuring occupant safety and minimizing damage to surrounding structures.
Implementation Method 1
a coating composition that comprises an inorganic filler, an inorganic binder, and chopped organic fibers... capable of withstanding high temperature (e.g. greater than 750° C....) particle ejection without perforation
Implementation Method 2
these materials must also be able to withstand low and high temperatures and humidities without degradation of their properties
Implementation Method 3
withstand the blast associated with a high energy battery thermal runaway event
Data Source
AI summary
The present invention describes a coating composition that when applied to a substrate is capable of withstanding high temperature particle ejection without perforation caused by a high energy thermal runaway event. The coating composition comprises an inorganic filler, an inorganic binder; and chopped organic fibers.