Foamed Epoxy Passage Insulation for Battery Gas Isolation

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Solution Overview

Problem

In electrically driven motor vehicles, thermal runaway of the battery can generate poisonous and hot gases that need to be isolated from the passenger compartment to ensure occupant safety.

Innovation Solution

An insulated passage system using an expanded foamed epoxy resin composition as an insulating element, which is applied in a non-expanded state and cured during vehicle painting, effectively blocking the passage to prevent gas propagation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a passage connects the battery region to the passenger compartment, then air permeability and ventilation are improved, but thermal runaway gases can propagate to the passenger compartment

Engineering Contradiction:

Improvegas propagation protectionVSAvoidpassage insulation implementation

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The insulating element is pre-installed in the passage before the battery is mounted in the vehicle. This preliminary action ensures that the passage is already insulated against thermal runaway gas propagation, while maintaining the ability to assemble the battery later without complex modifications.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The insulating element is made from a foamed material with porous structure that provides thermal insulation while allowing the passage to maintain its structural integrity. The porous foam material effectively blocks the propagation of hot gases while being manufacturable and installable in the passage.

Inventive Principle:

Principle #31Porous materials

2Object-affected harmful factors

If an insulating element is installed in the passage, then gas propagation is blocked, but installation complexity increases

Engineering Contradiction:

Improvethermal insulation effectivenessVSAvoidinsulation system structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The insulation system is segmented into a separate, standalone insulating element that can be independently installed in the passage. This segmentation simplifies the overall system structure by isolating the insulation function into a discrete component rather than integrating it into the passage walls or battery housing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A foamed insulating material is used to provide effective thermal insulation with a simple, single-piece structure. The foam material's cellular structure provides high insulation performance while maintaining a straightforward geometric form that is easy to install without complex assembly steps.

Inventive Principle:

Principle #31Porous materials

3Ease of manufacture

If known expanding materials are used for insulation, then manufacturing costs are reduced, but material authorization requirements increase complexity

Engineering Contradiction:

Improvematerial cost efficiencyVSAvoidmaterial approval status

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The insulating element is designed to be a universal component that can be used across different battery models and vehicle types. By creating a standardized insulation solution that fits various passage configurations, the need for model-specific material authorizations is reduced, while still providing effective insulation performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The insulating element can be produced using copying methods such as molding or casting from master patterns. This allows for rapid reproduction of the insulation component using established manufacturing processes and materials that are already approved for automotive use, avoiding the need for new material authorizations.

Inventive Principle:

Principle #26Copying

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 system provides a cost-effective and efficient insulation mechanism that withstands hot gases, using known materials to ensure passenger safety by blocking hazardous gases from the battery compartment.

Implementation Method 1

an expandable material (3) which is expandable under the action of heat to a state with a greater volume than before expansion

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

wherein the expanded material is a foamed and at least partially cured epoxy resin composition

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS20260048706A1Insulated passage system

Publication Date: 2026.02.19 SIKA TECH AG

AI summary

A system of an insulated passage in an electrically driven motor vehicle includes a passage which connects a first region to a second region, wherein the first region is air-permeable in the direction toward a battery of the motor vehicle and wherein the second region is air-permeable in the direction toward a passenger compartment of the motor vehicle. The system further includes an insulating element which includes an expanded material, wherein the expanded material closes the passage against the first region and wherein the expanded material is a one-component thermally cured epoxy resin composition.