Flame barrier material for a rechargeable electrical energy storage system

Abstract

A multilayer material for use as a thermal insulation barrier and/or flame barrier in a rechargeable electrical energy storage system is provided. The multilayer material comprises at least one inorganic fabric layer bonded to a nonwoven layer comprising inorganic particles and inorganic fibers by an inorganic adhesive, wherein the inorganic adhesive. The inorganic adhesive can be a modified inorganic adhesive comprising at least 99 wt. % inorganic constituents and an organic additive of at least 0.01 wt. % and less than 1 wt. % based on a total solids content of the inorganic adhesive.

1 . A multilayer material for use as a flame barrier in a rechargeable electrical energy storage system, the multilayer material comprising:
 at least one inorganic fabric layer bonded to a nonwoven layer comprising inorganic particles and inorganic fibers by an inorganic adhesive, wherein the inorganic adhesive is a modified inorganic adhesive comprising at least 99 wt. % inorganic constituents and an organic additive of at least 0.01 wt. % and less than 1 wt. % based on a total solids content of the inorganic adhesive, wherein the organic additive comprises a polyvinyl alcohol, and wherein the multilayer material is not punctured by a flame at a temperature of at least 1000° C. for a period of at least 10 minutes.   
     
     
         2 . The multilayer material according to  claim 1 , wherein the inorganic fabric comprises E-glass fibers, R-glass fibers, ECR-glass fibers, basalt fibers, leached and ion-exchanged fibers, ceramic fibers, silicate fibers, steel filaments or a combination thereof. 
     
     
         3 . The multilayer material according to  claim 1 , wherein the inorganic fabric is a glass fiber fabric. 
     
     
         4 . The multilayer material according to  claim 3 , wherein the glass fiber fabric is coated with calcium silicate coating. 
     
     
         5 . The multilayer material according to  claim 1 , wherein the at least one nonwoven layer comprises E-glass fibers, S-glass fibers, R-glass fibers, ECR-glass fibers, basalt fibers, ceramic fibers, polycrystalline fibers, non-bio-persistent fibers, alumina fibers, silica fibers or a combination thereof. 
     
     
         6 . The multilayer material according to  claim 1 , wherein the at least one nonwoven layer comprises an inorganic paper or an inorganic board. 
     
     
         7 . The multilayer material according to  claim 1 , wherein the nonwoven layer is an inorganic insulating paper comprising glass fibers and microfibers, inorganic particles and an organic adhesive binder. 
     
     
         8 . The multilayer material of  claim 1 , wherein the multilayer material provides electrical insulation with a minimum dielectric breakdown voltage of 2 kV. 
     
     
         9 . A multilayer material for use as a flame barrier in a rechargeable electrical energy storage system, the multilayer material comprising:
 an inorganic paper comprising glass fibers and microfibers, inorganic particles and an organic binder and   a surface coated glass fiber fabric layer bonded to a major surface of the inorganic paper by an inorganic adhesive, wherein the inorganic adhesive is a modified inorganic adhesive comprising at least 99 wt. % inorganic constituents and an organic additive of at least 0.01 wt. % and less than 1 wt. % based on a total solids content of the inorganic adhesive, wherein the organic additive comprises a polyvinyl alcohol, and wherein the multilayer material is not punctured by a flame at a temperature of at least 1000° C. for a period of at least 10 minutes.   
     
     
         10 . The multilayer material according to  claim 9 , wherein the glass fiber fabric is coated with calcium silicate coating. 
     
     
         11 . The multilayer material according to  claim 9 , wherein the organic additive is a fully hydrolyzed polyvinyl alcohol. 
     
     
         12 . The multilayer material according to  claim 9 , wherein the inorganic fabric comprises a thickness in the range of 0.3 to 3 mm. 
     
     
         13 . The multilayer material according to  claim 9 , wherein the inorganic fabric comprises a basis weight of above 400 g/m 2 . 
     
     
         14 . The multilayer material according to  claim 9 , wherein the at least one nonwoven layer comprises a weight in the range of 100 to 2500 g/m. 
     
     
         15 . The multilayer material according to  claim 9 , wherein the multilayer material comprises a total thickness of 0.7 to 5 mm. 
     
     
         16 . A multilayer material for use as a flame barrier in a rechargeable electrical energy storage system, the multilayer material comprising:
 a first inorganic fabric layer bonded to a first major surface of a nonwoven layer comprising inorganic particles and inorganic fibers by an inorganic adhesive; and   a second inorganic fabric layer bonded to a second major surface of the nonwoven layer by the inorganic adhesive,   wherein the inorganic adhesive is a modified inorganic adhesive comprising at least 99 wt. % inorganic constituents and an organic additive of at least 0.01 wt. % and less than 1 wt. % based on a total solids content of the inorganic adhesive wherein the organic additive comprises a polyvinyl alcohol, and wherein the multilayer material is not punctured by a flame at a temperature of at least 1000° C. for a period of at least 10 minutes.   
     
     
         17 . A rechargeable electrical energy storage system, comprising:
 at least one battery cell, and   the multilayer material of  claim 1  to provide a flame barrier during a thermal runaway event.   
     
     
         18 . The rechargeable electrical energy storage system according to  claim 17 , wherein the multilayer material is arranged with the inorganic fabric facing the at least one battery cell. 
     
     
         19 . The rechargeable electrical energy storage system according to  claim 17 , wherein the multilayer material is positioned between the at least one battery cell and a lid of the storage system. 
     
     
         20 . The rechargeable electrical energy storage system according to  claim 19 , wherein the multilayer material is attached to the lid with an adhesive.