Lightweight Composite Sheet with Thermally Expandable Flame Shielding
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Solution Overview
Problem
Conventional fiber-reinforced composite materials for high energy density batteries face challenges in achieving both high flame shielding property and light weight, with issues such as increased cost and weight due to the use of metal materials, and biopersistence concerns with existing flame retardants.
Innovation Solution
A composite sheet containing a thermoplastic resin and inorganic fibers, incorporating a thermally expandable flame retardant, which forms a dense char layer upon heating, providing both flame shielding and lightweight properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal materials are used for battery housing to achieve high flame shielding property, then flame shielding property is improved, but weight increases
Solution Approach 1:
The patent changes the material parameters by using thermoplastic resin with inorganic fibers instead of metal, and incorporates thermally expandable flame retardants that change state under heat to form protective char layers. This allows achieving flame shielding through chemical transformation rather than relying on metal density, thus reducing weight while maintaining safety.
Solution Approach 2:
The patent creates a composite material system combining thermoplastic resin, inorganic fibers, and thermally expandable flame retardants. This composite structure provides both the lightweight advantage of resin and the flame resistance needed for safety, eliminating the need for heavy metal housing while maintaining flame shielding property.
2Reliability
If refractory materials are used in combination with metal materials to improve flame shielding, then flame shielding property is improved, but cost and processability deteriorate
Solution Approach 1:
The patent merges the flame retardant function directly into the resin composition itself, rather than adding separate refractory material layers. The thermally expandable flame retardants are incorporated within the thermoplastic resin matrix, creating an integrated solution that simplifies manufacturing processes and reduces costs while maintaining flame shielding performance.
3Reliability
If conventional flame retardants are added to polypropylene resin to achieve flame retardancy, then flame shielding property is improved, but biopersistence issues arise
Solution Approach 1:
The patent changes the chemical composition parameters by selecting thermally expandable flame retardants with specific molecular structures that decompose into non-biopersistent substances. The flame retardants used (such as phosphorus-based compounds) transform under heat to form protective char layers and release non-harmful gases, eliminating the biopersistence problem associated with conventional halogenated flame retardants.
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 sheet achieves high flame shielding and light weight, with a density of 1.3 g/cm3 or less, while maintaining structural integrity and processability, effectively blocking flames for extended periods and reducing weight and cost.
Implementation Method 1
incorporating a thermally expandable flame retardant, which forms a dense char layer upon heating
Data Source
AI summary
Provided is a composite sheet containing a thermoplastic resin composition (X) and inorganic fibers (Y), in which the thermoplastic resin composition (X) contains a thermoplastic resin and a thermally expandable flame retardant, and the composite sheet has a density of 1.3 g/cm3 or less. It is possible to provide a composite sheet having high flame shielding property and light weight property.