Textile Sheet with Ceramic Coating for EV Thermal Protection
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Solution Overview
Problem
Existing heat and fire protection materials for electric vehicles, such as metal-plastic composite systems, face issues of high weight, lack of flexibility, and complex manufacturing processes, which hinder weight reduction and recyclability, while also failing to provide adequate protection against high temperatures and mechanical energies.
Innovation Solution
A textile fabric composed of needled layers of paraaramid-Preox fibers, with a ceramic coating on both sides, offering a lightweight, flexible, and highly effective solution for heat and fire protection, capable of withstanding high mechanical energies and temperatures up to 2200 °C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal-plastic composite materials are used for heat protection, then protective effect is improved, but weight increases
Solution Approach 1:
The patent uses a composite textile structure combining basalt fabric (for thermal stability and fire resistance), para-aramid fabric (for mechanical strength and heat resistance), and poly-p-phenylene-2,6-benzobisoxazole fabric (for chemical resistance and thermal stability). This multi-material composite achieves superior protective properties while maintaining low weight compared to metal-plastic composites.
2Reliability
If metal-plastic composite materials are used for heat protection, then protective effect is improved, but flexibility decreases
Solution Approach 1:
The patent employs flexible textile fabrics instead of rigid metal-plastic composites. The basalt, para-aramid, and poly-p-phenylene-2,6-benzobisoxazole fabrics provide protective functions while maintaining flexibility and conformability, allowing the material to adapt to various shapes and applications.
3Adaptability or versatility
If traditional textile materials are used, then flexibility is improved, but temperature resistance decreases
Solution Approach 1:
The patent combines multiple high-performance fibers with complementary properties: basalt fibers provide exceptional thermal stability and fire resistance (withstanding temperatures up to 1000°C), para-aramid fibers contribute heat resistance and mechanical strength, and poly-p-phenylene-2,6-benzobisoxazole fibers add chemical resistance and thermal stability. This composite achieves temperature resistance comparable to or exceeding metal materials while retaining textile flexibility.
4Ease of manufacture
If conventional manufacturing processes are used, then ease of manufacture is improved, but productivity decreases
Solution Approach 1:
The patent integrates multiple functional layers (basalt fabric, para-aramid fabric, poly-p-phenylene-2,6-benzobisoxazole fabric) into a single composite textile structure that can be manufactured in one continuous process. The needling technique bonds all layers simultaneously, eliminating sequential assembly steps and improving productivity while maintaining manufacturing simplicity.
5Reliability
If known protective materials are used, then fire resistance is improved, but volume increases
Solution Approach 1:
The patent achieves superior fire resistance in a thin, compact textile structure. The multi-layer composite of basalt, para-aramid, and poly-p-phenylene-2,6-benzobisoxazole fabrics provides excellent fire protection without the bulkiness of traditional insulating materials, minimizing volume while maximizing protective performance.
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 textile fabric provides enhanced mechanical strength, fire resistance, and thermal stability, allowing for timely evacuation in case of battery fires and offering a cost-effective, easily attachable solution for various applications, including electric vehicles and energy storage systems.
Implementation Method 1
the front side and the back side each have a ceramic coating
Implementation Method 2
capable of withstanding high mechanical energies and temperatures up to 2200 °C
Implementation Method 3
A textile fabric composed of needled layers of paraaramid-Preox fibers
Implementation Method 4
suitable for use, for example, in electric cars as a protective shield against high mechanical energies, for example against particle beams
Data Source
Figure 1
AI summary
A textile fabric characterized by the following features: a) a sheet-like basalt or silicate fabric (BG, SG) needled with a first layer (PPV1) of a loose mixture of paraaramid-preox fibers to form a first precursor (A), b) a sheet-like paraaramid fabric (PG) or poly-p-phenylene-2,6-benzobisoxazole fabric (PPBG) needled with a second layer (PPV2) of a loose mixture of paraaramid-preox fibers to form a second precursor (B), c) wherein the first and second precursors (A, B) are needled together to form a sheet-like third precursor (C), the layers (PPV1, PPV2) of loose mixtures of paraaramid-preox fibers facing each other, d) wherein the sheet-like third precursor (C) has a front side (VS) to which the basalt fabric (BG) is attached. shows and has a back side (RS) to which the para-aramid fabric (PG) faces, e) wherein the front side (VS) and the back side (RS) each have a ceramic coating (KB),as well as a method for producing such a textile surface structure.