Thermal Insulation for EV Battery Protection

Multi-layered insulation material for battery packs that reduces temperature fluctuations, maintains stable battery temperatures, prevents heat and chemical dissipation, and contains thermal runaway fires. The insulation has layers including nonwoven oxidized polyacrylonitrile fibers with high temperature resistance, wool paper/blankets, and metallic foil facing layers. This multi-layered insulation provides insulation, fire containment, and thermal runaway protection for batteries without active cooling systems.

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Battery pack design for improved insulation and structure in battery packs, energy storage devices, and vehicles. The battery pack has a cell group with cells arranged in a stack. The cells are surrounded by an insulating film. Instead of sticking an insulating film on the cell surface, the film is fixed to the cell using a gel layer. This eliminates the need for an adhesive layer between the insulating film and cell. The gel layer also helps prevent wrinkles and bubbles in the insulating film. The insulating film is fixed to the cell through the gel layer. This improves insulation and reduces the risk of delamination between the cell and insulating film. It also avoids using adhesives between the film and cell, which can weaken the structural strength of the pack.

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A thermal insulation cushion pad for battery modules that improves safety and longevity of battery packs by reducing thermal runaway propagation and cell-to-cell pressure impacts. The cushion pad is sandwiched between adjacent cells in a battery pack. It has layers of ceramic fiber cotton, silicone rubber, and glass fiber. The ceramic fiber provides thermal insulation, the silicone rubber absorbs expansion forces, and the glass fiber enhances thermal insulation. This cushion pad prevents heat and pressure from propagating between cells during thermal runaway, improving cell safety and pack stability.

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Battery design to prevent high voltage ignition between cells without increasing spacing and losing energy density. The battery has cells arranged with opposite poles facing each other. Insulation is provided between the cells, with part of it located between the facing poles. This prevents voltage breakdown between the cells without increasing intercell spacing.

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Battery pack design to improve energy density and safety without increasing pack thickness. The pack has stacked batteries with insulation between them. The insulation has notches at the sides of adjacent batteries that align. This allows the pack to have less overall insulation thickness compared to fully covering the sides. The notches reduce pack thickness while still electrically isolating the batteries. The notch areas balance to provide sufficient insulation.

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High-performance heat-insulating aluminum plate structure for the inner wall of electrical appliances like electric vehicles that can delay thermal runaway propagation in battery modules to prevent fires. The insulating plate has a panel fixed to the outer sides and a honeycomb layer with through-holes filled with silica aerogel. The closed honeycomb cells isolate and slow down heat spread between battery cells compared to solid aluminum. It buys time for passengers to escape if a cell goes thermal runaway.

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Battery design to improve safety by preventing short circuits between the bus bar and case. The battery has stacked cells with a converging component connecting the cell leads. An insulating piece is placed between the cell wall and converging component to isolate and insulate the wall from the converging part. This prevents short circuits between the bus bar and case.

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Anti-heat insulation battery pack for electric vehicles with improved thermal protection and mechanical strength. The pack has a multi-layer structure consisting of a heat-proof layer and a heat-insulating layer. The heat-proof layer is made of a ceramic slurry containing silicone resin and ceramic particles. It provides ablation resistance to protect the battery during high-temperature events. The heat-insulating layer is made of a nano-silica aerogel composite felt. It provides thermal insulation to prevent heat transfer. The pack structure allows the pack to withstand high temperatures without delamination, cracking, or burning through while maintaining strength and integrity.

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Flexible thermal insulator for electric vehicle battery packs that inhibits flame propagation between cells and prevents thermal runaway. The insulator has a composite wall with a flame retardant sheet, pressure-sensitive adhesive layers, and a scrim-reinforced polyetheretherketone layer or silicone rubber. The adhesive layers secure the insulator to the battery pack. A release film can be removed to expose the adhesive for attaching the insulator. The insulator separates cells and has dielectric properties to prevent internal shorts.

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Insulator for electric vehicle battery packs that inhibits flame propagation between cells and from the pack. The insulator has a composite wall made of layers like scrim-reinforced PEEK, silica fabric, pressure-sensitive adhesives, and release film. The layers provide thermal and dielectric protection while also allowing conformability around the pack shape. The layers prevent flame spread and provide electrical isolation. The silica fabric reinforces the insulator against deformation. The release film allows easy application to the pack surface. The insulator thickness is 5 mm or less.

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Insulating plate for battery, lithium ion battery, and battery pack to prevent short circuits, improve safety, and prevent explosions. The insulating plate has a two-layer structure with a first insulating plate and a second insulating plate sandwiched between the battery electrode group and the first plate. The second plate is made of a meltable resin with a lower melting point than the first plate. This prevents contact between bent positive electrode leads and negative electrodes. If the battery overheats, the second plate melts quickly to allow exhaust and prevent explosions.

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Airgel composite battery core insulation sheet to prevent thermal runaway and improve safety of electric vehicle batteries. The sheet has a sandwich structure with an airgel insulation core sandwiched between two packaging layers. The airgel provides high thermal insulation while the packaging layers enhance resistance to compression, bending, peeling, dust generation, and aging compared to traditional airgel materials. This improves the durability and reliability of the battery insulation compared to thick, fragile materials like silicone foam and mica boards.

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Ultra-thin high-temperature nano-insulation plate for battery core insulation that can withstand temperatures over 900°C without cracking or failing. The plate is made by compressing fumed silica powder between layers of packaging material. This provides a thin, lightweight insulation sheet with low thermal conductivity suitable for battery cores. The packaging material completely covers the fumed silica layer. The plate can be cut and sealed into a vacuum-packed battery core insulation sheet using barrier films. The fumed silica insulation prevents thermal runaway propagation between cells without sintering at high temperatures. The packaging prevents fumed silica sintering and cracking.

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Fireproof and heat insulating pad for lithium-ion batteries to prevent thermal runaway and fires. The pad has layers of microporous nanoplates, fire-resistant felt, insulation, and adhesives. The microporous nanoplates are made of nanoporous alumina or silica with fibers. The felt contains alumina fibers and endothermic fillers. The insulation layer and adhesives complete the pad. The microporous nanoplates prevent conductive heat transfer, the felt absorbs heat, and the insulation blocks radiant heat. The pad has densities and thicknesses optimized for battery applications.

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Insulating battery isolation system to reduce temperature fluctuations, prevent thermal runaway fires, and improve battery life. The system uses multi-layer materials with high temperature insulation properties. It includes nonwoven layers with fibers like oxidized polypropylene and polyacrylonitrile, high silica layers, and stainless steel foil facing layers. These materials provide insulation, fire resistance, and containment during thermal runaway to protect the battery and prevent fires spreading to other cells or the vehicle cabin.

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Battery design with improved thermal runaway mitigation to prevent spread of cell fires in multi-cell packs. The battery has a heat insulation layer on the top and sides of the cell with a thermal conductivity less than 0.2 W/mK. This slows down or isolates heat flow when thermal runaway occurs in a cell to prevent it spreading to adjacent cells. The insulation layer covers areas like the top and seals where flames or heat are most likely to break through. The lower thermal conductivity compared to conventional plastics improves thermal insulation and safety.

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Multi-layer insulation material for preventing thermal runaway in lithium-ion batteries. The material includes at least one insulating layer, at least one compressible pad, and optionally one or more layers with good heat dissipation properties. The insulating layer prevents short circuits, the compressible pad absorbs swelling during abuse, and the heat dissipation layers mitigate thermal runaway. The multi-layer design allows optimization of insulation, compression, and heat dissipation for battery safety.

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Encapsulating thermal insulation layers used between battery cells in energy storage systems to improve safety by preventing thermal runaway propagation. The insulation layers are surrounded by a support member and an encapsulation layer that contacts the support. This encloses the insulation and provides mechanical support while preventing particulate generation. The encapsulation can also have fire-resistant properties. The encapsulated insulation barriers are used between cells in battery modules to isolate and contain heat. The encapsulation prevents misalignment and compression issues during installation.

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A thin heat insulation member for battery cells that prevents thermal runaway spread between cells. The insulation has a mica plate base sandwiched between thin ceramic coatings. The mica goes between cells and the ceramic coatings face adjacent cells. The thin ceramic-mica-ceramic sandwich provides high insulation while allowing dense cell packing.

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Battery pack design with improved shock resistance and ease of manufacturing. The battery pack has a cell module with stacked cells, a connecting structure that electrically connects the cells in a perpendicular direction, and insulation between the cells. The insulation is placed between adjacent cells and solidified to prevent internal cell movement during shock. This prevents cell damage and pack failure. The insulation connects to the cell walls and adjacent structure to prevent excessive cell movement. The insulation also reduces manufacturing complexity by preventing cell misalignment during packing.

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