Ceramic-Microsphere Silicone Foam for Compressible Battery Thermal Barriers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermal barriers for lithium-ion batteries lack adequate heat insulation, flame resistance, and compressibility, particularly for high energy density battery packs, with materials like aerogel and silicone foam failing to meet these criteria.
Innovation Solution
A foamed material comprising polyorganosiloxane foam, fire retardant, and hollow ceramic particles, with specific weight and volume percentages, providing a thermal barrier that is insulating, flame-resistant, and compressible.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If aerogel or ceramic fiber is used as thermal barrier, then heat insulation is improved, but mechanical resilience deteriorates
Solution Approach 1:
The invention uses a composite material system combining polyorganosiloxane foam base material with dispersed hollow ceramic particles (25-300 μm). This composite structure integrates the thermal insulation properties of ceramic with the mechanical flexibility of silicone foam, resolving the contradiction between heat insulation and mechanical resilience. The hollow ceramic particles act as thermal barriers while the polyorganosiloxane matrix provides mechanical support and resilience.
2Temperature
If mica board is used as thermal barrier, then heat insulation is improved, but compressibility deteriorates
Solution Approach 1:
The invention incorporates hollow ceramic particles with internal voids and creates a porous foam structure with controlled cell morphology. This porous architecture allows the material to be compressed while maintaining thermal insulation, as the air pockets within the hollow particles and foam structure can be compressed without collapsing the overall thermal barrier function. The polyorganosiloxane matrix provides elastic recovery after compression.
3Ease of operation
If silicone blown foam is used as thermal barrier, then compressibility is improved, but heat insulation deteriorates
Solution Approach 1:
The invention enhances standard silicone foam by adding hollow ceramic particles (1-35 wt%) with specific size distribution (25-300 μm). These ceramic particles create additional thermal resistance pathways within the foam matrix, significantly improving heat insulation while the foam structure itself maintains compressibility. The composite structure allows the material to be compressed for battery assembly while providing superior thermal barrier performance.
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 foamed material effectively reduces surface temperature during thermal events, maintains compressibility, and prevents flame propagation, meeting the requirements for high energy density battery packs.
Implementation Method 1
aerogel and ceramic fiber suffer poor mechanical resilience... insufficient heat insulation to prevent thermal runaway
Implementation Method 2
from 1 to 30 weight percent of a fire retardant... flame resistant
Implementation Method 3
silicone blown foam provides adequate compressibility... suitable for batteries of low and moderate energy density
Data Source
AI summary
An insulating, compressible, and flame-resistant foamed material comprises a polyorganosiloxane foam, a fire retardant, and micron-sized hollow ceramic particles. The foamed material is useful for providing heat insulation, flame resistance, and compressibility for applications such as lithium-ion batteries.