Multilayer Thermal Barrier Material for Battery Runaway Containment

The thermal barrier is divided into multiple thin layers (first inorganic layer, second inorganic layer, organic layer) instead of using a single thick ceramic element. This segmentation allows each layer to contribute differently to the overall function while improving flexibility and ease of integration into battery packs.

The patent uses a composite structure combining inorganic materials (for thermal insulation) with an organic layer (for flexibility and bonding). This composite approach maintains the thermal insulation performance of inorganic materials while adding the flexibility and ease of integration provided by the organic component.

The thick thermal barrier is segmented into multiple thin layers that can be independently manufactured and then assembled. This reduces the processing difficulty of each individual layer while achieving the required overall thermal insulation performance through the combined thickness of all layers.

Instead of relying solely on increasing the thickness of a single barrier element, the patent uses a multi-layer approach where the thermal insulation is achieved through the cumulative effect of multiple thin layers in the thickness dimension, while each layer maintains simple processing characteristics.

The organic material is placed in a specific location (the organic layer between inorganic layers) where it provides flexibility, while the inorganic layers on the outer surfaces provide fire resistance. Each material is positioned where it best serves its primary function, creating a balanced composite structure.

The patent creates a composite structure where organic and inorganic materials work together synergistically. The inorganic layers provide fire resistance and thermal insulation, while the organic layer provides flexibility and bonding between layers, achieving both flexibility and fire resistance simultaneously.