Ceramizing Composite Thermal Barrier for High-Heat Protection
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Solution Overview
Problem
There is a growing need for improved thermal barrier designs that can effectively protect against high heat potential in applications such as electric vehicle battery packs and high-temperature cable protection, as existing solutions are inadequate in managing increasing heat growth.
Innovation Solution
A filler composition comprising a ceramization filler component, a reinforcement component, a flux component, and a flame retardant component, combined with a polymer-based matrix, is developed to create a composite material and composite material layer with enhanced thermal barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If existing thermal barrier designs are used, then basic thermal protection is provided, but they are inadequate in managing increasing heat growth from technology improvements
Solution Approach 1:
The patent employs a composite material system consisting of a polymer matrix combined with inorganic filler composition containing ceramization filler, reinforcement component, flux component, and flame retardant component. This composite structure provides superior thermal barrier performance compared to single-material solutions, enabling effective protection against high heat potential while maintaining structural integrity.
Solution Approach 2:
The invention optimizes the compositional parameters of the filler material by specifying precise weight percentage ranges for each component (ceramization filler: 50-90 wt.%, reinforcement: 0.1-10.0 wt.%, flux: 3.0-10.0 wt.%, flame retardant: 5.0-20.0 wt.%). These parameter adjustments enable the material to achieve enhanced thermal stability and maintain cold-side temperatures below 800°C during hot plate and torch exposure tests.
2Stability of the object's composition
If filler composition with high ceramization content is used to improve thermal stability, then thermal barrier properties are enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functional components into a single integrated filler composition that can be directly incorporated into the polymer matrix. The filler composition integrates ceramization filler, reinforcement component, flux component, and flame retardant component in predetermined ratios, eliminating the need for separate processing steps for each component and simplifying manufacturing while achieving superior thermal stability.
Solution Approach 2:
By defining specific compositional ranges for each filler component, the invention standardizes the material formulation, making it easier to manufacture consistently. The specified weight percentages ensure optimal thermal performance while facilitating straightforward mixing and processing during production.
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 composite material effectively maintains a cold-side temperature below 800°C during hot plate and torch exposure tests, achieving a V-O flammability rating and providing efficient thermal protection while maintaining suitable mechanical properties.
Implementation Method 1
a ceramization filler component at a content of at least about 50 wt. % and not greater than about 90 wt. % for a total weight of the filler composition
Implementation Method 2
The composite material effectively maintains a cold-side temperature below 800°C during hot plate and torch exposure tests
Data Source
AI summary
The subject application relates to a filler composition, composite material and composite material layer with thermal barrier properties. The present disclosure relates to a filler composition may include a ceramization filler component at a content of at least about 50 wt. % and not greater than about 90 wt. % for a total weight of the filler composition, a reinforcement component at a content of at least about 0.1 wt. % and not greater than about 10.0 wt. % for a total weight of the filler composition, a flux component at a content of at least about 3.0 wt. % and not greater than about 10.0 wt. % for a total weight of the filler composition, and a flame retardant component at least about 5.0 wt. % and not greater than about 20.0 wt. % for a total weight of the filler composition.