Fiber-Reinforced Rigid Insulation for Compact Thermal Batteries

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Solution Overview

Problem

Conventional thermal battery insulation materials have limitations in maintaining heat retention and mechanical integrity, leading to reduced operational life and increased size and mass, especially in smaller thermal batteries, while also posing safety risks due to heat escape.

Innovation Solution

Development of non-flexible composite insulation materials comprising a metal oxide matrix reinforced with a fibrous material and an opacifying compound, which are processed through heat treatment and compression to enhance thermal conductivity, mechanical integrity, and handleability, resulting in a material with low thermal conductivity and high flexural modulus.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional insulation materials (foam or fiber sheets) are used, then thermal insulation capacity is limited, but increasing thickness to improve insulation increases the volume and mass of the battery system

Engineering Contradiction:

Improveheat retentionVSAvoidinsulation volume

Core Design Contradiction:

Loss of energyVSVolume of stationary object

Solution Approach 1:

The patent applies composite materials by combining aerogel particles (providing exceptional thermal insulation) with a binding matrix material to create a composite insulation composition. This composite structure achieves superior insulation performance per unit volume compared to conventional foam or fiber sheets, allowing effective thermal management without increasing insulation thickness or volume.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent utilizes porous materials by incorporating aerogel particles into the insulation composition. Aerogels are highly porous materials with extremely low thermal conductivity, enabling the composition to achieve high insulation capacity in a compact form factor, thus improving heat retention without increasing the volume occupied by insulation material.

Inventive Principle:

Principle #31Porous materials

2Strength

If rigid insulation materials are used to improve structural integrity, then handleability and flexibility during installation deteriorate

Engineering Contradiction:

Improvemechanical integrityVSAvoidhandleability

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent applies parameter changes by adjusting the composition ratios of aerogel particles to binding matrix material, as well as modifying particle size distribution and curing parameters. These parameter adjustments enable the insulation composition to achieve optimal balance between mechanical strength (when set) and workability (when applied), allowing it to be easily conformable during installation yet structurally sound in service.

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If insulation thickness is increased to improve thermal containment, then the space available for battery components and cells is reduced

Engineering Contradiction:

Improvethermal containmentVSAvoidbattery module space

Core Design Contradiction:

Loss of energyVSVolume of moving object

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

4Ease of operation

If flexible insulation materials are used for easy installation, then mechanical strength and structural stability deteriorate

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidmechanical strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent applies dynamics by creating a material that transitions from a flexible, conformable state during application to a rigid, structurally sound state after curing. The composition can be applied in a pliable condition to conform to battery cell surfaces and contours, then sets to provide mechanical strength and structural stability, thus achieving both installation flexibility and mechanical integrity at different stages.

Inventive Principle:

Principle #15Dynamics

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 prolongs the operational time of thermal batteries, reduces heat escape risks, and allows for a smaller, lighter battery design while maintaining thermal safety, with improved mechanical properties and handleability compared to existing materials.

Implementation Method 1

exposing the aerogel composite to a heat treatment to remove organic moieties

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Implementation Method 2

mechanically compressing the aerogel composite, thereby increasing the density

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS20250002410A1Rigid, non-flexible fiber reinforced insulation composite

Publication Date: 2025.01.02 ASPEN AEROGELS INC

AI summary

The present disclosure relates to non-flexible composite insulation materials comprising a metal oxide matrix reinforced with a fibrous material embedded therein. Specifically, the present disclosure relates to use of the non-flexible composite insulation materials for thermal batteries and the like. The non-flexible composite insulation materials with low thermal conductivity provided herein is capable of meeting the mechanical requirements for thermal battery design yet provides improved handleability compared to the commercially available insulators.