Thermal Composite with Basalt Blanket for Battery Enclosure Fire Resistance
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Solution Overview
Problem
Existing thermal composites fail to effectively provide fire resistance and thermal insulation in applications exposed to high temperatures, such as battery enclosures and engine compartments, as they either lack sufficient heat protection or are too heavy due to the materials used.
Innovation Solution
A thermal composite comprising a substrate, primer layer, adhesive layers, and a blanket layer made of basalt or glass fibers, combined with a metal foil layer, which creates a consistent air gap and insulation to prevent heat penetration and self-extinguish flames within 2 minutes, while being lightweight and structurally efficient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional thermal composite materials are used to provide fire resistance and thermal insulation, then heat protection is improved, but weight increases
Solution Approach 1:
The patent uses a composite structure combining organic fiber blanket (for thermal insulation) with inorganic metal foil layer (for fire resistance and structural stability). This composite approach allows achieving both fire resistance and thermal insulation without using excessively heavy single-material solutions, as each layer contributes its specific properties synergistically
Solution Approach 2:
Different layers of the composite are assigned different functions: the organic blanket provides thermal insulation where heat blocking is needed, while the metal foil layer provides fire resistance and structural integrity where thermal stability is critical. This localized functional assignment optimizes weight by using materials only where their specific properties are most beneficial
2Temperature
If thick thermal insulation layers are used to prevent heat penetration, then thermal insulation is improved, but device complexity increases
Solution Approach 1:
The patent achieves effective thermal insulation with reduced thickness by combining organic fiber blanket with metal foil layer. The composite structure provides enhanced thermal performance per unit thickness compared to single-material solutions, reducing the overall thickness needed while maintaining insulation effectiveness
Solution Approach 2:
The patent adds a dimensional aspect by incorporating a metal foil layer that reflects radiant heat, complementing the conductive/convective insulation of the organic blanket. This multi-dimensional heat blocking approach (combining reflection from foil with insulation from blanket) achieves better thermal protection in a thinner overall structure
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 thermal composite effectively protects internal spaces from external flames by maintaining insulation and self-extinguishing properties, even at high temperatures, and is lighter than comparable materials, enhancing energy efficiency in mobile and stationary systems.
Implementation Method 1
The blanket layer includes basalt fibers or glass fibers... the heat/burn resistance, anti-oxidation, and flame arresting properties of the blanket layer enable the blanket layer to provide a consistent air gap or consistent insulation between the flame and the underlying substrate
Implementation Method 2
The metal foil layer defines an external surface to be exposed to a flame... the flame rapidly self-extinguishing... and thus protects the substrate from pyrolization, outgassing, and burning
Data Source
AI summary
An example of a thermal composite includes a substrate, a primer layer, a first adhesive layer, a blanket layer, a second adhesive layer, and a metal layer. The blanket layer includes basalt fibers or glass fibers. The thermal composite may be incorporated into a battery pack as a battery enclosure.