Stacked Mesh Fireproof Material for Lithium Battery Modules
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Solution Overview
Problem
Conventional fireproof materials for lithium battery modules are limited by high density and weight, rigidity, and inability to withstand temperatures above 400°C, making them unsuitable for lightweight, flexible, and high-temperature applications.
Innovation Solution
A fireproof material with a stacked mesh structure composed of oxidized fibers and silicate fibers, interwoven to form multiple layers with controlled thickness and density, allowing for high fire resistance, lightweight properties, and low thermal conductivity, produced through a process involving cotton opening, blending, carding, weaving, needling, and heat pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of inorganic powders is added to improve fire resistance, then fire resistance is improved, but material density and weight per unit area become too high
Solution Approach 1:
The patent uses a three-dimensional porous network structure formed by ultrasonic vibration of liquid crystal polymer fibers, creating a material with high porosity (70-80%). This porous structure provides fire resistance through the physical barrier and heat absorption capacity of the porous network, while simultaneously maintaining low density and weight because the porous structure contains大量 air pockets that reduce material density without compromising the fireproof barrier function.
Solution Approach 2:
The patent creates a composite material system consisting of liquid crystal polymer fibers (providing structural framework and fire resistance), inorganic powder fillers (providing fireproofing properties), and polymer resin matrix (providing binding and flexibility). This composite approach allows the material to achieve fire resistance through the synergistic effect of multiple components rather than relying solely on large amounts of inorganic powder, thus reducing overall density while maintaining fireproof performance.
2Stability of the object's composition
If the conventional fireproof material is made rigid to ensure structural stability, then structural stability is improved, but the material cannot be bent, limiting applicable end products
Solution Approach 1:
The patent incorporates polymer resin as a matrix material that binds the liquid crystal polymer fibers and inorganic powder fillers together, creating a flexible composite structure. The polymer resin matrix provides flexibility and bendability to the overall material, allowing it to be conformally applied to various battery pack designs while the embedded liquid crystal polymer fiber network maintains structural stability and fireproof integrity during bending.
Solution Approach 2:
The polymer resin acts as an intermediary material that mediates between the rigid liquid crystal polymer fiber network (providing structural stability) and the requirement for flexibility. The resin matrix allows the rigid fiber structure to be integrated into a flexible composite material, enabling the material to bend while maintaining the integrity of the fireproof barrier structure.
3Reliability
If the fireproof material thickness is increased to improve fire resistance, then fire resistance is improved, but the material occupies more space, failing to meet space-efficient requirements
Solution Approach 1:
The three-dimensional porous network structure created by ultrasonic vibration of liquid crystal polymer fibers provides exceptional fire resistance per unit thickness. The porous structure with 70-80% porosity creates a tortuous path for heat and flame propagation, enhancing fireproof performance while maintaining thin profile. The high surface area to volume ratio of the porous network intensifies the fire barrier effect, allowing thin layers to provide equivalent or superior fire protection compared to thicker conventional materials.
Solution Approach 2:
The patent transitions from a conventional two-dimensional planar fireproof layer to a three-dimensional porous network structure through ultrasonic vibration processing. This dimensional transformation creates a volumetric fire barrier within a thin profile, where the three-dimensional arrangement of fibers and pores provides enhanced fire resistance pathways without increasing the overall thickness of the material layer.
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 material achieves high fire resistance, lightweight properties, bendability, and low thermal conductivity, making it suitable for lithium battery modules, with the added advantage of quick mass production and low production costs.
Implementation Method 1
The fireproof material has an overall thermal conductivity of between 0.01 W/(m·K) and 0.8 W/(m·K)
Implementation Method 2
Each of the first fibers has a first refractory temperature of between 700° C. and 1,000° C. and each of the second fibers has a second refractory temperature of between 900° C. and 1,100° C.
Data Source
AI summary
A fireproof material used for a lithium battery module and a method for producing the same are provided. The fireproof material has a stacked structure formed by stacking multiple layers of mesh structures. Each layer of the mesh structures includes a plurality of first fibers and a plurality of second fibers. The first fibers are oxidized fibers, and the second fibers are silicate fibers. Each layer of the mesh structures is formed by interweaving the plurality of first fibers and the plurality of second fibers. The multiple layers of the mesh structures of the fireproof material have a stacked layer number of between 5 layers and 20 layers and a stacked layer thickness of between 0.3 mm and 5 mm. The fireproof material has a density of between 0.05 g/cm3 and 2 g/cm3 and a thermal conductivity of between 0.01 W/(m·K) and 0.8 W/(m·K).