Furan Thermoset Composite Shielding for Battery Thermal Runaway
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Solution Overview
Problem
Current materials used in battery housings, such as aluminum and organic polymer sheets, struggle to contain high temperatures and jet flames during thermal runaway events, posing safety risks and failing to meet stringent thermal runaway specifications, while composite materials with thermoplastic polymers and carbon fibers increase cost and weight without adequate thermal barrier performance.
Innovation Solution
A composite material comprising a thermoset layer made from furan-based resins and reinforcement fibers, with a minimum average length of 6 mm, provides enhanced thermal and mechanical properties, capable of withstanding high temperatures and jet flames, and is designed to contain heat and fire within a closed environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum or organic polymer sheet is used for battery housing, then weight is reduced, but thermal runaway containment capability deteriorates
Solution Approach 1:
The patent employs a composite material consisting of thermoset resin (epoxy, polyester, or vinyl ester) combined with reinforcement fibers (glass, carbon, or aramid) to create a battery housing that simultaneously achieves lightweight construction and superior thermal runaway containment. The composite structure provides both the weight reduction benefit of non-steel materials and the thermal protection previously only available with heavy steel housings.
2Reliability
If steel is used for battery housing, then thermal runaway containment capability is improved, but weight increases
Solution Approach 1:
The patent replaces heavy steel with a composite material system comprising thermoset resin and reinforcement fibers, achieving comparable or superior thermal runaway containment while significantly reducing weight. The thermoset matrix provides heat resistance and structural integrity during thermal events, while the fiber reinforcement maintains mechanical strength.
Solution Approach 2:
The patent utilizes the high glass transition temperature and thermal stability parameters of thermoset resins to achieve thermal runaway containment at lower weights. The thermoset polymer matrix maintains its structural properties at elevated temperatures, providing the necessary thermal barrier without requiring the mass of steel.
3Weight of moving object
If thermoplastic polymer with carbon fibers is used, then weight is reduced, but thermal barrier performance deteriorates
Solution Approach 1:
The patent transitions from thermoplastic to thermoset polymer matrix, fundamentally changing the thermal properties of the composite. Thermoset resins exhibit higher glass transition temperatures and superior heat resistance compared to thermoplastics, enabling the material to maintain structural integrity and provide effective thermal barrier performance at reduced weights.
Solution Approach 2:
The patent combines thermoset resin with reinforcement fibers to create a composite that simultaneously achieves lightweight construction and superior thermal barrier performance. The synergistic combination of the thermally stable thermoset matrix and the insulating properties of glass, carbon, or aramid fibers provides both weight reduction and enhanced thermal protection.
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 composite material effectively contains heat and fire, preventing thermal propagation and extending passenger evacuation time during a thermal runaway event, while being lightweight and environmentally friendly, suitable for battery applications in electric vehicles and aerospace.
Implementation Method 1
the composite material effectively contains heat and fire, preventing thermal propagation
Implementation Method 2
capable of withstanding high temperatures and jet flames
Data Source
AI summary
Use of a composite as a heat and fire shielding material particularly in batteries, wherein the composite comprises at least one layer of a thermoset material, wherein said at least one layer is based on an at least partial consolidation of a mixture of: a. one or more furan-based resins; b. one or more catalysts; and c. one or more reinforcement fibers; wherein at least 90 wt% of the one or more reinforcement fibers have an average length according to a gaussian normal distribution of at least 6 mm, preferably of at least 10 mm.