Fiber Fire Protection Material for Battery Swelling and Thermal Runaway
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Solution Overview
Problem
Existing fire protection materials for lithium-ion batteries are brittle and inflexible, leading to damage and loss of thermal insulation due to swelling of the cells during cycling and vibration, which can cause thermal runaway.
Innovation Solution
A fiber-containing fire protection material with compressible and mechanical strength properties, comprising a fiber matrix with additives, maintains thermal characteristics from the beginning to the end of the battery's life, providing flame resistance, low thermal conductivity, and electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fire protection materials are used, then flame resistance is provided, but the materials are brittle and fracture under stress from cell swelling and vibration
Solution Approach 1:
The patent uses a composite material consisting of ceramic fibers embedded in a polymer matrix. The ceramic fibers (such as alumina, silica, or magnesia) provide flame resistance and thermal insulation, while the polymer matrix (such as polyethylene, polypropylene, or polyester) provides mechanical flexibility and toughness. This composite structure allows the material to maintain both fire protection effectiveness and mechanical flexibility under stress from cell swelling and vibration.
2Temperature
If fire protection material is placed between cells, then thermal insulation is provided, but the material volume increases space consumption in the battery pack
Solution Approach 1:
The patent employs a porous structure within the fire protection material where ceramic fibers are distributed throughout a polymer matrix with intentional void spaces. This porous architecture reduces the overall density and volume of the material while maintaining effective thermal insulation through the ceramic fiber network. The polymer matrix fills the spaces between fibers, providing structural integrity without significantly increasing volume.
3Duration of action of stationary object
If the fire protection material is made flexible to accommodate cell swelling, then mechanical durability is improved, but thermal insulation performance may deteriorate
Solution Approach 1:
The patent applies local quality by concentrating the thermal insulation function in the ceramic fiber regions while allowing the polymer matrix regions to provide mechanical flexibility. The ceramic fibers are distributed throughout the material at higher concentrations in areas requiring thermal protection, while the polymer matrix provides flexibility where mechanical stress occurs. This spatial differentiation of material properties allows simultaneous achievement of thermal insulation and mechanical durability.
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 material effectively suppresses thermal runaway throughout the battery's life, maintains insulation despite swelling, and minimizes space consumption in the battery pack, while being blast-resistant and flexible.
Implementation Method 1
maintains thermal characteristics from the beginning to the end of the battery's life, providing flame resistance, low thermal conductivity
Implementation Method 2
A fiber-containing fire protection material with compressible and mechanical strength properties, comprising a fiber matrix with additives
Implementation Method 3
providing flame resistance, low thermal conductivity, and electrical insulation
Data Source
AI summary
A fire protection material includes at least 10 wt % of inorganic fibers, at least 5 wt % of an additive dispersed within the inorganic fibers, the additive selected from fibers, particles, platelets, aerogels, a foam, or combinations thereof; and at least 2 wt % of a binder dispersed within the inorganic fibers. The inorganic fibers, additive, and binder account for at least 60 wt % of the fire protection material.