Crosslinked Polyketone Molded Articles for Thermal Runaway Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current thermoplastics used in electrical devices, such as electric vehicles and power tools, face limitations in temperature resistance and mechanical stability, particularly during thermal runaway events, where they can melt and lose functionality, while crosslinked thermosets offer improved heat resistance but are difficult to process and handle safely.
Innovation Solution
A flame-retardant molded article comprising a polymer matrix of crosslinked aliphatic polyketone (PK) combined with a special diamine source as a crosslinking agent to form imine groups, along with a flame retardant, enhancing mechanical and thermal properties while maintaining processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastics are used in electrical devices, then processability and ease of manufacture are improved, but temperature resistance and mechanical stability deteriorate during thermal runaway events
Solution Approach 1:
The patent applies parameter changes by modifying the molecular structure of thermoplastics through crosslinking. The polyketone polymer chains are chemically crosslinked to form a three-dimensional network structure, which fundamentally changes the material's thermal properties while maintaining its processability during molding. This crosslinking transformation enables the material to resist high temperatures and maintain mechanical stability during thermal runaway events.
Solution Approach 2:
The patent creates a composite material system combining polyketone polymer chains with crosslinking agents (diamines). The crosslinked polyketone forms a composite structure where the polymer matrix is reinforced by crosslinking bonds, achieving both thermoset-like temperature resistance and thermoplastic-like processability. The flame retardant additives further enhance this composite structure to prevent combustion.
2Temperature
If crosslinked thermosets are used to improve heat resistance, then temperature resistance is improved, but ease of manufacture and safety deteriorate due to difficult processing and handling
Solution Approach 1:
The patent applies dynamics by creating a material that transitions from a processable state to a stable state. During molding, the polyketone remains in a flexible, processable thermoplastic state. After molding, thermal or chemical crosslinking transforms it into a rigid, heat-resistant thermoset structure. This dynamic transformation allows the material to exhibit different properties at different stages of its lifecycle, combining the advantages of both thermoplastics and thermosets.
3Object-affected harmful factors
If flame retardants are added to thermoplastics, then flammability is reduced, but mechanical stability and structural integrity deteriorate at high temperatures
Solution Approach 1:
The patent merges multiple functions into a single integrated system. The crosslinked polyketone structure simultaneously provides mechanical stability, heat resistance, and flame retardancy. The crosslinking network prevents polymer chain degradation at high temperatures, maintaining structural integrity while the flame retardant additives suppress combustion. This unified approach eliminates the trade-off between flame retardancy and mechanical stability that exists in conventional thermoplastic formulations.
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 improved temperature resistance, reduced flammability, and increased stiffness at high temperatures, ensuring the materials remain dimensionally stable and non-burnable, effectively preventing the spread of fires and maintaining structural integrity during thermal runaway events.
Implementation Method 1
A flame-retardant molded article comprising a polymer matrix of crosslinked aliphatic polyketone (PK) combined with a special diamine source as a crosslinking agent to form imine groups
Implementation Method 2
enhancing mechanical and thermal properties while maintaining processability... ensuring the materials remain dimensionally stable and non-burnable, effectively preventing the spread of fires
Data Source
AI summary
A device for storage, generation, transmission, distribution and/or other use of electrical energy, comprising a flame retardant molded article, comprising a polymer matrix containing a crosslinked aliphatic polyketone (PK) in combination with at least one flame retardant and to a method for improving the flame retardant properties of molded articles for electrical devices. In addition electric vehicles, battery energy storage systems, power tools and devices for power generation and to parts therof, comprising a flame retardant molded article, comprising a polymer matrix containing a crosslinked aliphatic polyketone (PK) in combination with at least one flame retardant.