Circumferentially continuous, axially and radially stretchable, fire suppressing, puncture resistant, dielectric knit sleeve
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Solution Overview
Problem
Current protective sleeves for elongate members in electric vehicle battery systems lack dielectric, fire suppressant, and puncture-resistant properties while also being bulky and unsightly, failing to ensure the vehicle remains drivable during thermal runaway conditions.
Innovation Solution
A stretchable knit sleeve with a circumferentially continuous outer surface made from multifilament flame-resistant yarn, coated with an impervious elastomeric layer, providing snug fit and enhanced flame resistance, impact resistance, and protection against contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional protective sleeves are used to protect elongate members, then protection against impact and abrasion is provided, but the sleeves are bulky and unsightly
Solution Approach 1:
The patent employs a thin-walled knit sleeve constructed from flexible elastomeric material that provides protective functions without the bulk of conventional sleeves. The knit structure allows the sleeve to maintain strength while minimizing volume, creating a low-profile protective covering that conforms to the elongate member.
Solution Approach 2:
The sleeve utilizes composite construction combining knit fabric with elastomeric coating to achieve both protection and low profile. The multi-layer composite structure integrates different material properties to provide impact resistance, abrasion resistance, and fire suppression while maintaining a compact form factor.
2Reliability
If protective sleeves provide fire suppressant and dielectric protection, then safety during thermal runaway is improved, but the sleeves become more cumbersome and bulky
Solution Approach 1:
The sleeve is designed as a multi-functional protective component that simultaneously provides fire suppression, dielectric protection, impact resistance, and abrasion resistance. By integrating multiple protective functions into a single sleeve structure, the design avoids the need for multiple separate protective layers that would increase complexity and bulk.
Solution Approach 2:
The elastomeric coating applied to the knit sleeve provides fire suppressant and dielectric properties while the knit substrate provides mechanical strength. This composite material approach delivers multiple protective functions in a unified, non-cumbersome structure.
3Ease of operation
If the knit sleeve is made stretchable to conform to bus bar shapes, then ease of assembly and low profile are achieved, but protection against puncture and tearing may be reduced
Solution Approach 1:
The knit sleeve utilizes the inherent flexibility of knit fabric construction to achieve stretchability and conformability to various bus bar shapes. The elastic nature of the knit structure allows easy assembly while maintaining adequate mechanical strength through proper material selection and construction.
Solution Approach 2:
The combination of knit fabric substrate with elastomeric coating creates a composite structure where the knit provides stretchability and the coating enhances puncture and tear resistance. This composite approach maintains both ease of assembly and protective strength.
4Duration of action of moving object
If the sleeve provides protection for 5 minutes during thermal runaway, then vehicle drivability is maintained, but the material requirements become more stringent and complex
Solution Approach 1:
The elastomeric coating serves multiple protective functions simultaneously, including fire suppression for the required 5-minute duration, dielectric protection, and thermal resistance. By using a multi-functional material, the patent meets the extended protection requirement without proportionally increasing complexity.
Solution Approach 2:
The selection of specific elastomeric materials with appropriate thermal stability, fire resistance, and dielectric properties enables the sleeve to maintain protection for 5 minutes during thermal runaway. Material parameter optimization achieves the extended duration requirement while managing complexity.
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 sleeve allows the electric vehicle to remain powered for at least 5 minutes during thermal runaway, enabling safe maneuvering and evacuation, while maintaining a low profile and preventing electrical interference and contamination.
Implementation Method 1
An impervious coating is provided to extend about the outer surface of the knit wall to prevent the ingress and penetration of electric dust, particles, smoke through the knit wall
Implementation Method 2
The knit wall is formed at least in part by multifilament flame-resistant yarn having a denier between 30 tex to 420 tex
Implementation Method 3
The knit structure of the knit wall is stretchable axially and radially, thereby allowing the knit wall easily to flex and be easily assembled into close conforming, wrinkle-free relation about the bus bar
Data Source
AI summary
A sleeve for providing protection to a bus bar interconnecting cells of a battery of an electric vehicle has a knit wall having a circumferentially continuous outer surface extending along a longitudinal axis between opposite open ends. The knit wall is formed by multifilament flame-resistant yarn having a denier between 30 tex to 420 tex. An impervious coating extends about the entirety of an outer surface of the knit wall.