Intumescent Insulating Lining for Battery Housing Fire Protection
Solution Overview
Problem
Existing battery housings face challenges in withstanding accidents or exothermic reactions due to the limitations of granular zeolites, which can be dislodged by flames and fail to maintain structural integrity at high temperatures, particularly in aluminum cases.
Innovation Solution
A multi-layer insulating covering with a thermally activatable intumescent material, sandwiched between fabric or mat layers, which expands to reduce thermal conductivity and effectively contain flames, while being easy to process and apply, and includes an adhesive for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If granular zeolites are used as thermally active material, then thermal insulation performance is improved, but processing difficulty increases and structural integrity deteriorates under fire exposure
Solution Approach 1:
The patent combines granular zeolites with a binding agent to form a composite material. The binding agent holds the granular zeolites together in a matrix structure, enabling easy processing and application while maintaining the thermal insulation properties of the zeolites. This composite approach resolves the contradiction between using effective thermal insulation material and achieving ease of manufacture.
Solution Approach 2:
The patent applies the thermally active material layer as a coating or lining on the inner wall of the housing. This thin film or layer approach allows the material to conform to complex geometries and provides easy application while maintaining thermal insulation performance. The layered structure enables simple manufacturing processes compared to bulk material processing.
2Temperature
If granular zeolites are used in the insulating layer, then thermal insulation is improved, but reliability deteriorates due to material dislodgement by flames
Solution Approach 1:
The binding agent in the composite material creates a cohesive matrix that anchors the granular zeolites, preventing them from being dislodged by flames. This composite structure maintains both the thermal insulation performance of the zeolites and the reliability of the insulating layer during fire exposure.
Solution Approach 2:
The binding agent is incorporated in advance into the thermally active material composition to provide structural support and prevent material dislodgement before fire exposure occurs. This preliminary structural reinforcement ensures reliability during subsequent fire events while maintaining thermal insulation properties.
3Ease of manufacture
If aluminum housing is used, then ease of manufacture is improved, but reliability deteriorates due to melting at temperatures above 660°C
Solution Approach 1:
The insulating lining with thermally active material acts as an intermediary layer between the aluminum housing and the external fire source. This intermediate layer absorbs and reflects heat, protecting the aluminum housing from direct thermal exposure and preventing melting, while allowing the housing to maintain its manufacturing advantages.
Solution Approach 2:
The thermally active material is applied in advance to the housing interior to create a protective barrier before fire exposure. This preliminary protective layer prevents direct heat transfer to the aluminum housing, ensuring reliability during fire events while preserving the ease of manufacture of aluminum components.
4Reliability
If multi-layer insulating lining is applied, then fire resistance is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functional layers into a single integrated insulating lining assembly. The thermally active material layer, binding agent, and substrate are merged into a unified structure that can be applied as one component, reducing the complexity of handling and installation while maintaining the fire resistance benefits of multi-layer construction.
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 provides enhanced fire resistance and thermal insulation, protecting the battery housing from internal and external threats by reducing the available fire volume and maintaining structural integrity during exothermic reactions.
Implementation Method 1
a thermally activated material, which changes its volume under the influence of heat and/or fire, favorably alters the thermal conductivity of the entire insulating cladding through its expansion
Implementation Method 2
the second layer 2 comprises a thermally activated material 2a. The thermally activated material 2a changes its volume under the influence of heat and/or fire
Data Source
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AI summary
An insulating lining (10, 10', 10") for equipping a housing (6, 6', 6"), comprising at least two layers (1, 2, 3, 4), wherein a first layer (1) is connected to a second layer (2) and wherein the second layer (2) comprises a thermally activatable material (2a), is characterized in view of the objective of providing an insulating lining for housings, in particular battery housings, which makes it possible to equip a housing effectively for virtually any case of an accident or the occurrence of an exothermic reaction, in that the thermally activatable material (2a) changes its volume under the influence of heat and/or fire.