Multilayer Battery Pack Insulator for Extended Flame Resistance
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Solution Overview
Problem
Existing fiberglass fabric insulation in electric vehicle battery packs fails to effectively inhibit flame propagation at high temperatures, allowing flames to spread outwardly from the battery pack in less than 5 minutes at 1000° C.
Innovation Solution
A multilayer thermal insulator composed of interlaced mineral yarns with silicone and mica-based flame-resistant coatings, a pressure-sensitive adhesive, and stitched filaments, which prevents flame propagation for at least 10 minutes at 800-1500° C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fiberglass fabric insulation is used, then protection against contamination and environmental temperatures is provided, but flame propagation protection is insufficient
Solution Approach 1:
The patent applies composite materials by combining multiple layers with different properties: an inner layer of mineral fibers for thermal insulation, an intermediate layer of intumescent material for flame expansion and barrier formation, and an outer layer of flame-retardant fabric for structural integrity and external flame resistance. This multi-layer composite structure addresses the insufficient flame protection of single-material fiberglass while maintaining thermal insulation capabilities.
Solution Approach 2:
The patent applies local quality by assigning specific functions to different layers: the inner layer focuses on thermal insulation close to the battery, the intermediate layer provides intumescent expansion specifically at the flame interface, and the outer layer offers structural stability and external flame resistance. Each layer is optimized for its specific location and function within the thermal insulation system.
2Reliability
If thicker insulation is used to improve flame resistance, then flame propagation is better inhibited, but the insulator occupies more space and reduces flexibility
Solution Approach 1:
The patent applies phase transitions through the intumescent intermediate layer, which undergoes a dramatic volume expansion when exposed to heat or flame. This intumescent transformation creates a thick, insulating char layer in situ, providing enhanced flame resistance without requiring the insulator to be thick in its uncompressed state. The phase transition allows the material to achieve fire protection equivalent to much thicker non-intumescent materials.
Solution Approach 2:
The patent applies segmentation by dividing the insulation into three distinct functional layers rather than using a single thick layer. This segmentation allows each layer to be optimized for its specific function while keeping the overall thickness minimal. The layered structure enables the system to achieve superior flame resistance through coordinated action of multiple thin layers rather than relying on one thick layer.
3Reliability
If multiple layers are used to improve flame protection, then flame propagation is better prevented, but the manufacturing complexity increases
Solution Approach 1:
The patent applies merging by combining multiple functional requirements into a single integrated multilayer assembly. The inner mineral fiber layer, intermediate intumescent layer, and outer flame-retardant fabric layer are bonded together to form a unified insulator that provides thermal insulation, flame expansion, and structural protection simultaneously. This merged structure simplifies installation and handling compared to separate components while maintaining the benefits of multiple functional layers.
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 multilayer insulator effectively contains and prevents flame propagation from electric vehicle battery packs for extended periods, maintaining the outer surface temperature below 500° C. and protecting passengers from fire and heat.
Implementation Method 1
the fiberglass insulator can result in a thermal runaway condition originating in any one of the cells of the battery pack, such that flame propagates outwardly from the battery pack
Implementation Method 2
A flexible multilayer battery pack insulator for an electric vehicle includes: a flexible multilayer wall including a plurality of layers
Implementation Method 3
An adhesive layer is bonded to the outer surface of the outer layer
Data Source
AI summary
A flexible multilayer battery pack insulator for an electric vehicle having a multilayer wall including a plurality of layers. The plurality of layers includes an inner layer of mineral material having an inner surface and an outer surface, and an outer layer of mineral material having an inner surface and an outer surface. A flame-resistant coating, including silicone and mica, bonded to at least one of the plurality of layers. An adhesive layer bonded to the outer surface of the inner layer, and at least one filament fixing the plurality of layers to one another.