Fiber Fire Barrier Composite for Li-Ion Thermal Runaway Protection
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Solution Overview
Problem
Existing materials used in thermal management systems for lithium-ion batteries fail to provide effective thermal insulation and structural integrity while preventing thermal runaway propagation, as they either melt at high temperatures or shed fibers, and combinations of these materials are difficult to bond due to flammability constraints.
Innovation Solution
A fire protection article combining a fire barrier made of non-combustible fibers with a passive thermal insulator using non-meltable oxidized polyacrylonitrile fibers, secured with a thermoplastic fluoropolymer binder, provides a thin yet effective barrier with high thermal insulation and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fire protection articles use traditional foam materials and application methods, then fire protection function is provided, but material waste occurs and application precision is poor leading to inconsistent coverage
Solution Approach 1:
The fire protection article is segmented into a reusable applicator component and a replaceable foam material component. The applicator includes a reservoir, pump, and spray mechanism that can be reused multiple times, while only the foam material cartridge needs replacement. This segmentation reduces material waste by eliminating the need to discard the expensive applicator hardware with each foam cartridge.
Solution Approach 2:
The pump system acts as an intermediary mechanism that precisely metered dispenses foam material from the cartridge through the spray nozzle. This intermediary device enables controlled foam application at desired locations and quantities, improving application precision and reducing both material waste and inconsistent coverage.
2Ease of manufacture
If traditional fire protection articles require multiple components and assembly steps, then functionality is achieved, but device complexity increases and ease of manufacture decreases
Solution Approach 1:
The applicator and foam material cartridge are merged into a single integrated assembly where the cartridge inserts directly into the applicator reservoir. The pump system integrates the dispensing mechanism within the applicator body, eliminating the need for separate assembly of multiple independent components and simplifying both manufacturing and user assembly.
Solution Approach 2:
The applicator is designed as a universal platform that can accept different types of foam material cartridges through a standardized interface. This multi-functionality allows the same applicator hardware to work with various foam formulations and viscosities, reducing device complexity while maintaining versatility.
3Adaptability or versatility
If fire protection articles use fixed foam material properties, then consistency is maintained, but adaptability to different fire scenarios and material viscosities decreases
Solution Approach 1:
The pump system is designed with adjustable parameters that allow dynamic control of foam dispensing rate, pressure, and atomization. This enables the same foam material to be adapted for different application scenarios by adjusting pump settings rather than changing material properties, maintaining material consistency while increasing versatility.
Solution Approach 2:
The system allows parameter changes in the dispensing process (flow rate, pressure, spray pattern) to adapt to different foam material viscosities and fire scenarios. The pump mechanism can be adjusted to accommodate various foam formulations without compromising application quality, enabling adaptability while maintaining controlled consistency through parameter optimization.
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 effectively prevents thermal runaway propagation in lithium-ion batteries by maintaining structural integrity and providing high thermal insulation, with a time to break of at least 10 seconds at 1100°C, while minimizing fiber shedding.
Implementation Method 1
The pump is configured to deliver a controlled amount of foam material through the nozzle
Implementation Method 2
provides fire protection at a desired location
Data Source
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AI summary
A fire protection article is provided that includes a fire barrier comprising a plurality of non-combustible fibers, and a passive thermal insulator coupled to the fire barrier and comprising a plurality of non-meltable fibers. Optionally, the fire protection article displays a time to break in the 1100℃ Break Strength Test of at least 10 seconds or a minimum tensile strength at 150℃ of at least 5 kPa. Optionally, the fire barrier comprises substantially continuous fibers that are mutually entangled. The fire barrier and passive thermal insulator can be mutually secured using a suitable polymeric binder, such a thermoplastic fluoropolymer binder. The combination of a relatively thin fire barrier with a comparatively thicker passive thermal insulator can provide thermal runaway protection in lithium-ion battery applications, structural integrity and a high degree of thermal insulation in the event of fire exposure.