MULTILAYER BATTERY PACK INSULATOR WITH MECHANICALLY JOINED LAYERS
A flexible multilayer battery pack insulator for an electric vehicle has a multilayer wall including a plurality of layers of interlaced mineral material including an inner layer having a first exposed, outwardly facing surface and an outer layer having a second exposed, outwardly facing surface. A first flame-resistant coating is bonded to at least one of the plurality of layers. A pressure-sensitive adhesive is bonded to the first exposed, outwardly facing surface of the inner layer. At least one filament fixes the plurality of layers to one another.
1 . A flexible multilayer battery pack insulator for an electric vehicle, comprising:
a multilayer wall including:
a plurality of layers of interlaced mineral material, said plurality of layers including an inner layer having a first exposed, outwardly facing surface and an outer layer having a second exposed, outwardly facing surface;
a first flame-resistant coating bonded to at least one of said plurality of layers;
a pressure-sensitive adhesive bonded to said first exposed, outwardly facing surface of said inner layer; and
at least one filament fixing said plurality of layers to one another.
2 . The flexible multilayer battery pack insulator of claim 1 , wherein said plurality of layers of interlaced mineral material further includes an intermediate layer sandwiched between said outer layer and said inner layer.
3 . The flexible multilayer battery pack insulator of claim 2 , wherein said interlaced mineral material of said intermediate layer is woven ceramic yarn.
4 . The flexible multilayer battery pack insulator of claim 1 , wherein said interlaced mineral material of said inner layer is woven fiberglass yarn.
5 . The flexible multilayer battery pack insulator of claim 1 , wherein said interlaced mineral material of said outer layer is woven silica yarn.
6 . The flexible multilayer battery pack insulator of claim 2 , wherein said outer layer, said intermediate layer, and said inner layer are not bonded to one another with an adhesive material.
7 . The flexible multilayer battery pack insulator of claim 1 , wherein said pressure-sensitive adhesive layer is the only adhesive layer of said multilayer wall.
8 . The flexible multilayer battery pack insulator of claim 2 , wherein said first flame-resistant coating is bonded to said second exposed, outwardly facing surface of said outer layer.
9 . The flexible multilayer battery pack insulator of claim 8 , further including a second flame-resistant coating bonded to said intermediate layer.
10 . The flexible multilayer battery pack insulator of claim 9 , wherein said interlaced mineral material of said intermediate layer is encapsulated by said second flame-resistant coating.
11 . The flexible multilayer battery pack insulator of claim 9 , wherein said second flame-resistant coating is one of silica, vermiculite, and graphite.
12 . The flexible multilayer battery pack insulator of claim 1 , wherein said first flame resistant coating is a silicone-based coating.
13 . The flexible multilayer battery pack insulator of claim 12 , wherein said first flame resistant coating has a weight between about 50 gsm to 600 gsm.
14 . The flexible multilayer battery pack insulator of claim 1 , further including a second flame-resistant coating bonded to said inner layer.
15 . The flexible multilayer battery pack insulator of claim 14 , wherein said second flame-resistant coating is sandwiched between said inner layer and said outer layer in abutting relation with said inner layer and said outer layer.
16 . The flexible multilayer battery pack insulator of claim 15 , wherein said first flame resistant coating is a silicone-based coating.
17 . The flexible multilayer battery pack insulator of claim 16 , wherein said second flame resistant coating is a silicone-based coating.
18 . The flexible multilayer battery pack insulator of claim 15 , wherein said interlaced mineral material of said inner layer is interlaced mineral yarns of silica and/or ceramic.
19 . The flexible multilayer battery pack insulator of claim 18 , wherein said interlaced mineral material of said outer layer is interlaced mineral yarns of silica and/or ceramic.
20 . A method of constructing a flexible multilayer battery pack insulator, comprising:
interlacing mineral material to form an outer layer having an outer surface and an inner surface;
bonding a first flame-resistant coating to the outer surface of the outer layer;
interlacing mineral material to form an inner layer;
arranging the outer layer and the inner layer in overlying relation with one another;
stitching at least one filament and fixing the outer layer and the inner layer to one another to form a multilayer wall;
bonding a pressure-sensitive adhesive to the inner layer; and
cutting the multilayer wall to size.