Flexible multilayer material resistant to explosion of an electric battery
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Solution Overview
Problem
Existing mechanical and thermal shields for electric batteries, such as mica plates and multi-layer materials, are either too rigid or fail to withstand the extreme conditions of a battery 'blast' phenomenon, and are cumbersome to adapt to complex battery geometries.
Innovation Solution
A multi-layer material composed of alternating layers of crosslinked silicone resin and silica or alumina fabric impregnated with expandable graphite particles, providing flexibility and resistance to temperatures exceeding 1500°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mica plates are used to form a shield, then mechanical and thermal integrity is guaranteed, but the shield becomes too rigid to adapt to complex battery geometries
Solution Approach 1:
The shield is divided into multiple modular units (2-4 units per battery) that can be independently positioned and adjusted. Each unit contains mica plates embedded in a flexible support structure, allowing the shield to conform to complex geometries while maintaining the protective properties of mica plates.
Solution Approach 2:
The shield combines mica plates with a flexible support structure made of heat-resistant materials. This composite construction integrates the high thermal and mechanical strength of mica with the flexibility and adaptability of the support structure, resolving the contradiction between rigidity and adaptability.
2Adaptability or versatility
If mica plates are cut and assembled to fit complex battery shapes, then adaptability is improved, but manufacturing time increases and weak zones appear at junctions
Solution Approach 1:
The shield is divided into multiple modular units (2-4 units per battery) that can be independently positioned and adjusted. Each unit contains mica plates embedded in a flexible support structure, allowing the shield to conform to complex geometries while maintaining the protective properties of mica plates.
Solution Approach 2:
Multiple mica plates are embedded within a single flexible support structure to form integrated modular units. This merging eliminates the need for separate assembly of individual mica plates, reducing manufacturing time and eliminating weak zones at junctions while maintaining adaptability to complex geometries.
3Manufacturing precision
If a dedicated mold is used to form a shield from composite material, then manufacturing precision is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The shield is divided into multiple modular units (2-4 units per battery) that can be independently positioned and adjusted. Each unit contains mica plates embedded in a flexible support structure, allowing the shield to conform to complex geometries while maintaining the protective properties of mica plates.
Solution Approach 2:
The flexible support structure with embedded mica plates serves as both the forming tool and the final protective component. This universal approach eliminates the need for dedicated molds for each battery shape, reducing device complexity and manufacturing time while maintaining manufacturing precision through the inherent flexibility of the support structure.
4Adaptability or versatility
If flexible multi-layer materials are used to adapt to any shape, then adaptability is improved, but resistance to extreme blast temperatures is reduced
Solution Approach 1:
The shield combines mica plates with a flexible support structure made of heat-resistant materials. This composite construction integrates the high thermal and mechanical strength of mica with the flexibility and adaptability of the support structure, resolving the contradiction between rigidity and adaptability.
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 resists the 'blast' phenomenon of electric batteries while adapting to any battery geometry without additional shaping, maintaining flexibility and mechanical integrity.
Implementation Method 1
particles of graphite expandable from a temperature higher than a crosslinking temperature of said resin
Implementation Method 2
a layer of crosslinked silicone resin comprising particles of expandable graphite
Implementation Method 3
a layer of silica or alumina fabric or knit
Data Source
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AI summary
The invention relates to a multilayer material comprising n basic units with n a non-zero natural number, a basic unit consisting of a laminate comprising in order: - a layer (7) of crosslinked silicone resin comprising graphite particles expandable from a temperature above a crosslinking temperature of said resin, - a layer (5) of impregnated silica or alumina fabric or knit, the fabric or knit being provided with interstices all impregnated with a crosslinked silicone resin comprising graphite particles expandable from a temperature above a crosslinking temperature of said resin, in which: - the number n of basic units is between 1 and 5 inclusive, - the nth basic unit being covered with another layer (7') of crosslinked silicone resin also comprising graphite particles expandable from a temperature above a crosslinking temperature of said resin,so as to form a laminate consisting of alternating layers of resin and fabric or knit material.