CN-224232771-U - Flexible multi-layer battery pack insulator for electric vehicle

Abstract

A flexible multi-layer battery insulator for an electric vehicle has a multi-layer wall including a first layer of interwoven mineral material having a first inner surface and a first outer surface, a first flame retardant coating bonded to the first outer surface, a second layer of interwoven mineral material having a second inner surface and a second outer surface, a second flame retardant coating bonded to the second outer surface, and a silicone foam intermediate layer sandwiched between the first inner surface of the first layer and the second inner surface of the second layer.

Inventors

• Zobar Hassan
• Chai Yinfang

Assignees

• 系统保护集团美国有限责任公司

Dates

Publication Date

20260512

Application Date

20250422

Claims (10)

1. 1. A flexible multi-layer battery pack insulator for an electric vehicle, comprising: a multi-layer wall, the multi-layer wall comprising: a first layer having a first inner surface and a first outer surface; a first flame retardant coating bonded to the first outer surface; a second layer having a second inner surface and a second outer surface; a second flame retardant coating bonded to the second outer surface, and A silicone foam intermediate layer sandwiched between the first and second interior surfaces.
2. 2. The flexible multilayer battery insulator of claim 1, wherein the first flame retardant coating and the second flame retardant coating are one of silicone, acrylic, or polymer.
3. 3. The flexible multilayer battery insulator of claim 2, wherein the first layer and the second layer have a density of 50-1100 gsm.
4. 4. The flexible multilayer battery insulator of claim 3, wherein the first flame retardant coating and the second flame retardant coating each have a thickness of 0.1-2.0 mm.
5. 5. The flexible multilayer battery insulator of claim 4, wherein the intermediate layer has a density of 500-1500kg/m 3 .
6. 6. The flexible multilayer battery insulator of claim 5, wherein the intermediate layer has a thickness of 0.5-12.5 mm.
7. 7. The flexible multilayer battery insulator of claim 1, further comprising a polymer film encapsulating the multilayer wall.
8. 8. The flexible multilayer battery insulator of claim 7, wherein the polymer film has a thickness of 0.010-0.051mm and is heat shrunk around the multilayer wall.
9. 9. The flexible multilayer battery insulator of claim 1, wherein the first layer and the second layer are formed as one of a woven mineral fabric, a knitted mineral fabric, or a non-woven mineral fabric.
10. 10. The flexible multilayer battery insulator of claim 1, wherein the first layer, the second layer, and the intermediate layer are quilted with one of polymer yarns, coated mineral yarns, or uncoated mineral yarns.

Description

Flexible multi-layer battery pack insulator for electric vehicle Technical Field The present utility model relates generally to electric vehicle battery thermal insulators and, more particularly, to thermal insulators for inhibiting flame initiation and propagation between cells within a battery module of an electric vehicle. Background In electric vehicles, including hybrid vehicles having an electric motor that is intermittently used when the internal combustion engine is off, the primary power source for operating the vehicle is provided by one or more battery packs. As shown at 12 in fig. 2A-2C, each battery pack includes a plurality of modules 14, each module 14 containing a plurality of cells 16, the cells 16 being arranged in stacked relation to one another and electrically connected in series or parallel with one another. While the battery 16 is well suited to providing the power required to operate the vehicle as intended, unexpected and undesirable problems may occur, such as during charging or when the module is impacted (e.g., upon a vehicle crash). For example, during charging, individual cells 16 tend to expand, and if expanded too much, high voltages may develop between adjacent cells 16, ultimately potentially resulting in damage to one or more of the cells 16. The resulting damage can reduce the performance and life of the battery 16 and the battery pack 12. In addition, the resulting damage may lead to thermal runaway between the cells 16 and ultimately between the modules 14, such as propagating a flame from a single module 14 (fig. 2A) and to an adjacent module (fig. 2B and 2C). It is desirable to provide thermal insulation between individual cells that inhibits damage to the cells during cell expansion and further inhibits flame propagation between cells and between battery modules, such as when individual cells are damaged. In particular, it is desirable to prevent flame propagation between the battery and the battery module when exposed to a flame at a temperature of 1000 ℃ to 1400 ℃ for 10 minutes or more from a distance of about 25 mm. Disclosure of utility model It is an object of the present disclosure to provide a flexible multilayer material for an electric vehicle battery pack that is at least satisfactory for inhibiting flame propagation between cells within a battery module, between battery modules, and from the battery pack for 10 minutes or more at temperatures of 1000-1400 ℃. It is another object of the present disclosure to provide a flexible multi-layer material between cells for an electric vehicle battery pack that is highly compressible in thickness, has a thin, uncompressed low profile (thickness) to minimize the amount of space occupied by thermal insulation between the cells, and is economical in manufacture and use. An aspect of the present utility model provides a flexible multi-layered battery pack insulator for an electric vehicle, hereinafter referred to as an insulator, which is disposed between stacked cells within a battery module of a battery pack. The insulator has a multi-layer wall including a first layer of interwoven mineral material having a first inner surface and a first outer surface, a first flame retardant coating bonded to the first outer surface, a second layer of interwoven mineral material having a second inner surface and a second outer surface, a second flame retardant coating bonded to the second outer surface, and a silicone foam intermediate layer sandwiched between and abutting the first inner surface and the second inner surface of the first layer. According to another aspect of the utility model, the first flame retardant coating and the second flame retardant coating are one of silicone, acrylic or polymer. According to another aspect of the utility model, the first layer and the second layer have a density of 50-1100 gsm. According to another aspect of the utility model, the first flame retardant coating and the second flame retardant coating each have a thickness of 0.1mm to 2.0 mm. According to another aspect of the utility model, the intermediate layer has a density of 500kg/m 3 to 1500kg/m 3. According to another aspect of the utility model, the intermediate layer has a thickness of 0.5mm to 12.5 mm. According to another aspect of the utility model, the insulator may further comprise a polymer film encapsulating the multilayer wall. According to another aspect of the utility model, the polymer film encapsulating the multi-layer wall has a thickness of 0.010-0.051 mm. According to another aspect of the utility model, the first layer of interlaced mineral material and the second layer of interlaced mineral material are formed as one of a woven fabric, a knitted fabric, or a nonwoven fabric. According to another aspect of the utility model, the first layer, the second layer, and the intermediate layer may be quilted with one of a polymer yarn, a coated mineral yarn, or an uncoated mineral yarn. Drawings The above and other aspects