CN114788075A - 用于介电绝缘的紫外线涂层 - Google Patents
用于介电绝缘的紫外线涂层 Download PDFInfo
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- CN114788075A CN114788075A CN202080084730.8A CN202080084730A CN114788075A CN 114788075 A CN114788075 A CN 114788075A CN 202080084730 A CN202080084730 A CN 202080084730A CN 114788075 A CN114788075 A CN 114788075A
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Abstract
描述了一种可UV固化的介电涂层。可固化涂层可以包括一种或多种丙烯酸酯单体、氨基甲酸酯预聚物、交联剂、至少一种增粘剂、光引发剂和任选的一种或多种填料和/或添加剂。所述涂层可用于使电池组电池和电池组绝缘,例如使电动汽车中使用的电池组电池和电池组绝缘。所述涂层易于施加并快速固化。即使在暴露于潮湿条件后,固化的涂层也可以具有高粘合强度。
Description
相关申请的交叉引用
本申请要求于2019年12月9日提交的美国临时专利申请号62/945,322的优先权,其公开内容通过引用全文并入本文。
技术领域
本文公开的主题涉及可紫外线(UV)辐射固化的绝缘涂层,特别是用于电池组的介电绝缘的可UV固化的涂层和施加此类涂层的方法。
背景技术
在电动汽车电池组和其他类型的电池组中,单个电池组电池、侧壁、冷却板和其他装置等组件与其他组件电绝缘以防止短路,从而提高电池组的安全性和耐用性。对这些组件进行电绝缘的当前工艺包括粉末涂覆或使用聚对苯二甲酸乙二醇酯(PET)涂膜。虽然粉末涂覆是一种常见的工艺,但这通常需要高温和更长的固化时间。由于电池通常不适用于这些高温,因此粉末涂覆传统上仅限于电池组内的非电池硬件。
因此,电动汽车内部使用的电池组电池(例如棱柱形、袋状和圆柱形电池组电池)通常被包裹在PET膜/带中以提供绝缘保护。电池盒内使用的冷却板通常也用PET或粉末涂层包裹或层压,以提供类似的介电保护。电池组电池也经常用导热、电绝缘的粘合剂/灌封材料相互粘结并粘结到冷却板上。理想的是这些材料不会脱粘以在导热粘合剂/灌封材料和电池之间形成间隙。当间隙形成时,可能会产生更大的热阻抗,并因此存在热失控。
更具体地,用于绝缘电池组电池的PET膜可包括PET层和压敏粘合剂(PSA)层。在电池组中,PSA层可以与一个电池组电池的电池组电池壁/基材(例如铝、钢、复合材料等)接触,并且PET层可以与热管理粘合剂/灌封材料接触,其本身可以直接定位在第二个涂有PET膜的电池组电池的PET层附近。使用PET膜对电池组电池进行绝缘可能涉及半手动安装,并且可能导致在高温/高湿条件下的附着力差。此外,PET的低表面能使其难以可靠地粘结。传统上,粘合剂和灌封材料制造商试图强化他们的粘合剂以更好地粘结到PET包裹的电池上。然而,汽车会受到许多冲击事件(例如坑洼、减速带、事故等)的影响,因此有很多机会使粘结不良的电池组电池组件从系统脱粘并从系统中带走热量。
因此,存在对可用于涂层/绝缘电池组电池和电池组组件的额外介电涂层的持续需求,特别是那些还可以使制造/组装工艺更快和/或更简单的介电涂层。
发明内容
此发明内容部分列出了本发明公开的主题的若干实施方案,并且在许多情况下列出了这些实施方案的变化形式和排列组合。此发明内容部分仅仅是众多和变化的实施方案的示例。提及给定实施方案的一个或多个代表性特征同样是示例性的。这样的实施方案通常可以存在或不存在所提到的特征;同样,这些特征可以应用于本发明公开的主题的其他实施方案,无论是否在本发明的发明内容中列出。为避免过度重复,此发明内容部分并未列出或建议此类特征的所有可能组合。
在一些实施方案中,本发明公开的主题提供了一种可固化涂层,其包含一种或多种丙烯酸酯单体、光引发剂、氨基甲酸酯预聚物、交联剂、一种或多种增粘剂和任选的一种或多种填料和/或一种或多种添加剂。在一些实施方案中,一种或多种丙烯酸酯单体包含反应性稀释剂。在一些实施方案中,所述反应性稀释剂包括丙烯酸异冰片酯、丙烯酸异辛酯和甲基丙烯酸甲酯(MMA)中的至少一种。
在一些实施方案中,光引发剂包括UV活化光引发剂。在一些实施方案中,氨基甲酸酯预聚物包含聚醚氨基甲酸酯二丙烯酸酯。在一些实施方案中,交联剂包含聚二季戊四醇六丙烯酸酯(dipentaerythritol hexacrylate)(DPHPA)。在一些实施方案中,一种或多种增粘剂包括甲基丙烯酸缩水甘油酯、甲基丙烯酸2-羟乙酯(HEMA)磷酸酯、环氧硅烷和甲基丙烯酸(MAA)中的至少一种。
在一些实施方案中,可固化涂层进一步包含除酸剂。在一些实施方案中,除酸剂选自包含磷酸锌、氧化锌和钼酸锌的组中。在一些实施方案中,可固化涂层包含一种或多种填料。在一些实施方案中,一种或多种填料包含未处理的亲水气相二氧化硅和/或经处理的疏水气相二氧化硅和/或霞石正长岩。
在一些实施方案中,可固化涂层是100%固体涂层。在一些实施方案中,固化涂层在约100微米厚度时具有约5千伏(kV)至约10kV的击穿电压。在一些实施方案中,固化涂层在85℃和85%相对湿度下老化长达1000小时后仍保持粘性。在一些实施方案中,固化涂层没有针孔、气泡并且包括良好的边缘覆盖。
在一些实施方案中,本发明公开的主题提供涂有介电涂层的层的电池组电池或其他电池组件,其中介电涂层是通过固化可固化涂层的层而形成的反应产物,该可固化涂层包含一种或多种丙烯酸酯单体、光引发剂、氨基甲酸酯预聚物、交联剂、一种或多种增粘剂和任选的一种或多种填料和/或一种或多种的添加剂。在一些实施方案中,所述介电涂层的层具有约25微米至约200微米的厚度。
在一些实施方案中,本发明公开的主题提供了一种用介电涂层涂覆基材的方法,该方法包括将可固化涂层的层施加到基材表面,其中可固化涂层包含一种或多种丙烯酸酯单体、光引发剂、氨基甲酸酯预聚物、交联剂、一种或多种增粘剂和任选的一种或多种填料和/或一种或多种添加剂;以及将可固化涂层暴露于紫外线辐射,从而形成带涂层的基材。在一些实施方案中,基材包括金属表面,任选地其中所述金属是铝。在一些实施方案中,基材包括电池组电池或电池组的组件。
在一些实施方案中,所述方法进一步包括由带涂层的基材形成电池组件。
在一些实施方案中,通过喷涂、辊涂或浸涂来施加可固化涂层的层。在一些实施方案中,可固化涂层的层具有约25微米至约200微米的厚度。在一些实施方案中,UV辐射由汞灯提供。
因此,本发明公开的主题的一个目的是提供可固化涂层(例如,可UV固化的介电涂层)和相关方法和涂覆材料。这个和其他目的通过本发明公开的主题全部或部分地实现。此外,本发明公开的主题的目的已经在上面阐明,在研究了以下描述和实施例之后,本发明公开的主题的其他目的和优点对于本领域技术人员将变得显而易见。
附图说明
图1是用介电涂层绝缘的两个电池组电池的电池组电池组件界面的示意图,该介电涂层作为本发明公开的主题的可紫外线(UV)固化涂层组合物的反应产物形成。
具体实施方式
现在将在下文更全面地描述本发明公开的主题,其中描述了本发明公开的主题的一些但非全部实施方案。实际上,本发明公开的主题可以以许多不同的形式体现,并且不应被解释为限于本文所阐述的实施方案;相反,提供这些实施方案是为了使本公开满足适用的法律要求。
I.定义
本文所使用的术语仅出于描述特定实施方案的目的,而不旨在限制本公开的主题。
除非下文另有定义,否则本文使用的所有技术和科学术语旨在具有与本领域普通技术人员通常理解的相同含义。对本文采用的技术的引用意在指本领域中通常理解的技术,包括对那些技术的变化或对本领域技术人员显而易见的等效技术的替代。尽管相信以下术语对于本领域普通技术人员很好理解,但提出以下定义是为了便于解释本发明公开的主题。
在描述本发明公开的主题时,将理解公开了许多技术和步骤。这些技术中的每一种都具有各自的益处,并且每种都可以与其他公开的技术中的一种或多种、或在一些情况下与全部的其他公开的技术组合使用。
因此,为了清楚起见,这里的描述将避免以不必要的方式重复各个步骤的每个可能的组合。然而,在阅读说明书和权利要求时应该理解这样的组合完全在本发明和权利要求的范围内。
遵循长期存在的专利法惯例,当在包括权利要求书的本申请中使用时,术语“一(a)”、“一个(an)”和“该(the)”是指“一个或多个”。因此,例如,提及的“一个组分”包括多个这样的组分,等等。
除非另有说明,否则说明书和权利要求书中使用的所有表示成分的量、反应条件等的数字应当理解为在所有情况下都由术语“约”修饰。因此,除非相反地指出,否则本说明书和所附权利要求书中所阐述的数值参数是近似值,其可根据由本公开的主题寻求获得的所需性质而变化。
如本文所用,术语“约”在指组合物、剂量、质量、重量、厚度、温度、时间、体积、浓度、百分比等的值或量时,意在涵盖以下变化:在一些实施方案中为±20%,在一些实施方案中为±10%,在一些实施方案中为±5%,在一些实施方案中为±1%,在一些实施方案中为±0.5%,在一些实施方案中为指定量的±0.1%,因为这样的变化适合于实现所公开的方法或采用所公开的组合物。
与“包括”、“含有”或“其特征在于”同义的术语“包含”是包括性的或开放式的,并且不排除附加的、未列举的元件或方法步骤。“包含”是权利要求语言中使用的技术术语,是指所提到的要素是必不可少的,但可以添加其他要素并且仍然形成权利要求范围内的构架。
如本文所用,短语“由...组成”不包括权利要求中未指定的任何要素、步骤或成分。当“由……组成”一词出现在权利要求正文的从句中而不是紧跟在前序部分后面时,它仅限定该从句中规定的要素;并未从整个权利要求中排除其他要素。
如本文所用,短语“基本上由...组成”将权利要求的范围限定为指定的材料或步骤,以及不会实质性影响要求保护的主题的基本和新颖性特征的那些。
关于术语“包括”、“由……组成”和“基本上由……组成”,在本文中使用这三个术语之一的情况下,本发明公开和要求保护的主题可以包括使用其他两个术语中的任一个。
如本文所用,当在实体列表的上下文中使用术语“和/或”时,是指实体单独或组合存在。因此,例如,短语“A、B、C和/或D”包括单独的A、B、C和D,而且还包括A、B、C和D的任何和所有组合和子组合。
如本文所用,术语“烃基”是指包括C1-20(含端值)、线性(即“直链”)、支化的、或环状的、饱和或至少部分且在一些情况下完全不饱和(即烯基和炔基)烃链,包括(例如)甲基、乙基、丙基、异丙基、丁基、异丁基、叔丁基、戊基、己基、辛基、乙烯基、丙烯基、丁烯基、戊烯基、己烯基、辛烯基、丁二烯基、丙炔基、丁炔基、戊炔基、己炔基,庚炔基和丙二烯基。“支化”是指其中诸如甲基、乙基或丙基之类的低级烃基附接至线性烃基链的烃基。“低级烃基”是指具有1至约8个碳原子,例如1、2、3、4、5、6、7或8个碳原子的烃基(即C1-8烃基)。“高级烃基”是指具有约10至约20个碳原子,例如10、11、12、13、14、15、16、17、18、19或20个碳原子的烃基。在某些实施方案中,“烃基”特别是指C1-8直链烃基。在其他实施方案中,“烃基”特别是指C1-8支链烃基。
烃基可以任选地被一个或多个烃基取代基取代(“取代的烃基”),烃基取代基可以相同或不同。术语“烃基取代基”包括但不限于烃基、取代的烃基、卤素、芳基氨基、酰基、羟基、芳氧基、烃氧基、烷硫基、芳硫基、芳烷氧基、芳烷硫基、羧基、烷氧基羰基、氧代和环烷基。在一些实施方案中,沿着烃基链可以任选地插入一个或多个氧、硫或取代或未取代的氮原子,其中氮取代基是氢、低级烃基(在本文中也称为“烷基氨基烷基”)或芳基。
因此,如本文所用,术语“取代的烃基”包括如本文所定义的烃基,其中烃基的一个或多个原子或官能团被另一原子或官能团取代,所述另一个原子或官能团包括(例如)烃基、取代的烃基、卤素、芳基、取代的芳基、烃氧基、羟基、硝基、氨基、烷基氨基、二烷基氨基、硫酸酯和巯基。
“烃氧基(alkoxyl)”是指一种烃基-O-基团,其中烃基如前所述。如本文所用,术语“烃氧基”可以指(例如)甲氧基、乙氧基、丙氧基、异丙氧基、丁氧基、叔丁氧基和戊氧基。术语“烃氧基(alkoxy)”和“烃氧基(oxyalkyl)”可以与“烃氧基”交换使用。
术语“硅基”是指包含硅原子(Si)的基团。
术语“硅烷”是指包含硅原子的分子。
如本文所用,术语“硅氧基”和“硅基醚”是指包括硅-氧(Si-OR)键的基团或化合物,其中R是有机基团,例如取代或未取代的烃基或芳基(即甲基、乙基、苯基等)。在一些实施方案中,该术语是指包含一个、两个、三个或四个与硅原子键合的烃氧基、芳烷氧基或芳氧基的化合物。各烷氧基、芳烷氧基或芳氧基可以相同或不同。
如本文所用,术语“氨基甲酸酯”是指含有氨基甲酸酯基团(--NH--CO--O--)的化合物。
如本文所用,“单体”是指可以进行聚合从而为大分子的基本结构贡献结构单元(即,原子或原子团)的分子。
如本文所用,“大分子”是指相对分子质量高的分子,其结构包含来自相对分子质量低的分子(例如单体和/或低聚物)的多个重复单元。
“低聚物”是指具有中等相对分子质量的分子,其结构包含少量(例如,2、3、4、5、6、7、8、9或10个)来自相对分子质量较低的分子的重复单元。
“聚合物”是指包含大分子的物质。在一些实施方案中,术语“聚合物”可以包括低聚物分子和具有更多数量(例如,>10、>20、>50、>100)重复单元的分子。在一些实施方案中,“聚合物”是指具有至少10个重复单元的大分子。
“共聚物”是指来自多于一种单体的聚合物。
“分支点”(或“连接点”)是指聚合物链(例如,主链)上连接有支链的点。“支链”,也称为“侧链”、“接枝”或“悬垂链”,是来自大分子链的单体分支、低聚分支或聚合分支。在一些实施方案中,在聚合物主链聚合之后,接枝被添加到聚合物主链上的反应性基团。低聚支链可称为“短链支链”,而聚合支链可称为“长链支链”。
“链”是指在两个边界构成单元之间包含构成单元的线性或支化序列的大分子、低聚物或嵌段的全部或部分,其中两个边界构成单元可以包含端基、分支点或它们的组合。
“主链”或“骨架”是指所有其他链都被认为是从其悬垂的线性链。
II.可紫外线固化的绝缘涂层
在一些实施方案中,本发明公开的主题提供了在固化时形成介电涂层的可固化涂层(例如,可辐射固化涂层),其中该介电涂层具有良好的粘附性和环境耐受性。在一些实施方案中,可辐射固化涂层是紫外线(UV)可固化涂层,例如,其可在暴露于UV能量的数秒内固化。
在一些实施方案中,介电涂层作为丙烯酸树脂的自由基或阳离子聚合的反应/聚合产物而形成。在一些实施方案中,固化的介电涂层具有与PET相当的介电性能和高表面能。与通常用作电池组的介电涂层的PET膜相比,该涂层对金属基材(例如铝)的粘附性提高,和/或在干燥和/或潮湿条件下(例如,85℃、85%相对湿度(RH))老化后的粘附性提高。
在一些实施方案中,本发明公开的可固化涂层包含:(i)一种或多种丙烯酸酯单体;(ii)光引发剂;(iii)氨基甲酸酯预聚物;(iv)交联剂;(v)一种或多种增粘剂。此外,可固化涂层可任选地包括一种或多种填料和/或一种或多种添加剂。
如本文所用,术语“丙烯酸酯单体”是指丙烯酸酯单体(例如,丙烯酸烷基酯单体)和相应的甲基丙烯酸酯单体。在一些实施方案中,一种或多种丙烯酸酯单体包含至少两个或至少三个(或更多)丙烯酸酯(或甲基丙烯酸酯)基团。因此,在一些实施方案中,丙烯酸酯单体可以是多官能的。在一些实施方案中,一种或多种丙烯酸酯单体中的一种或多种是反应性稀释剂,即可以降低可固化涂层制剂的粘度并且还在固化期间反应/聚合以成为固化涂层的一部分的化合物。丙烯酸酯单体可以是单官能或多官能的(例如,二丙烯酸酯或三丙烯酸酯)。
在一些实施方案中,一种或多种丙烯酸酯单体是单官能丙烯酸烷基酯或单官能甲基丙烯酸酯,即,含有一个丙烯酸酯或甲基丙烯酸酯基团和烷基部分的化合物。例如,单官能丙烯酸烷基酯单体具有结构CH2=CH-C(=O)-O-R,其中R是烷基;单官能甲基丙烯酸烷基酯单体具有结构CH2=C(CH3)-C(=O)-O-R,其中R为烷基。在一些实施方案中,烷基部分包括1至20个碳原子。在一些实施方案中,烷基部分包含6至18个碳原子(即,6、7、8、9、10、11、12、13、14、15、16、17或18个碳原子)。在一些实施方案中,烷基部分包含8至16个碳原子。所述烷基可以是直链的、支链的或环状的。
合适的丙烯酸酯单体包括但不限于丙烯酸己酯;甲基丙烯酸己酯;丙烯酸环己酯;甲基丙烯酸环己酯;丙烯酸2-乙基己酯;甲基丙烯酸2-乙基己酯;丙烯酸异辛酯;甲基丙烯酸异辛酯;丙烯酸辛酯;甲基丙烯酸辛酯;丙烯酸癸酯;甲基丙烯酸癸酯;丙烯酸异癸酯;甲基丙烯酸异癸酯;丙烯酸异冰片酯;甲基丙烯酸异冰片酯;丙烯酸月桂酯;甲基丙烯酸月桂酯;丙烯酸十八酯;甲基丙烯酸十八酯。在一些实施方案中,可以基于它们对固化涂层的玻璃化转变温度(Tg)的影响来选择一种或多种丙烯酸酯单体,例如以平衡或改变固化涂层的硬度或柔韧性。例如,添加丙烯酸异冰片酯可以提高Tg,从而提高固化涂层的硬度。添加丙烯酸异辛酯可以降低Tg并增加固化涂层的柔韧性。
在一些实施方案中,一种或多种丙烯酸酯单体包括反应性稀释剂,其包含丙烯酸异冰片酯、丙烯酸异辛酯和甲基丙烯酸甲酯(MMA)中的至少一种。在一些实施方案中,一种或多种丙烯酸酯单体包括丙烯酸异冰片酯和丙烯酸异辛酯。在一些实施方案中,一种或多种丙烯酸酯单体进一步包括MMA。
在一些实施方案中,一种或多种丙烯酸酯单体占总可固化涂层组合物的约30重量%至约90重量%。在一些实施方案中,一种或多种丙烯酸酯单体占总可固化涂层组合物的约40重量%至约50重量%(例如,占总可固化涂层组合物的约40、41、42、43、44、45、46、47、48、49或约50重量%)。在一些实施方案中,一种或多种丙烯酸酯单体占总可固化涂层组合物的约44重量%至约47重量%。
可以使用任何合适的辐射活化光引发剂。例如,合适的辐射活化光引发剂包括当暴露于可见光或紫外光时反应形成自由基或阳离子的化合物。在一些实施方案中,光引发剂是UV活化的光引发剂。示例性光引发剂包括但不限于二苯甲酮、苯乙酮衍生物,例如α-羟基烷基苯基酮、安息香烷基醚和苯偶酰缩酮、单酰基氧化膦和双酰基氧化膦。其他合适的光引发剂包括巯基苯并噻唑、巯基苯并噁唑和六芳基双咪唑。例如,光引发剂可选自包括(但不限于):1-羟基环己基苯基酮、2-甲基-1-[4-(甲硫基)苯基]-2-吗啉代丙-1-酮、2-苄基-2-N,N-二甲基氨基-1-(4-吗啉代苯基)-1-丁酮、50重量%的1-羟基环己基苯基酮和50重量%的二苯甲酮的组合、2,2-二甲氧基-2-苯基苯乙酮、25重量%的双(2,6-二甲氧基苯甲酰基-2,4-,4-三甲基戊基)氧化膦和75重量%的2-羟基-2-甲基-1-苯基-丙-1-酮的组合、BAPO和α-羟基酮的共混物、(2-羟基-2-甲基-1-苯基-1-丙烷、50重量%的2,4,6-三甲基苯甲酰基二苯基-氧化膦和50重量%的2-羟基2-甲基-1-苯基-丙-1-酮的组合、混合的三芳基锍六氟锑酸盐和混合的三芳基锍六氟磷酸盐。在一些实施方案中,光引发剂是双(2,4,6-三甲基苯甲酰基)-苯基氧化膦(由美国北卡罗来纳州夏洛特的IGM Resins以商品名Omnirad819出售)。
在一些实施方案中,光引发剂的含量可以为可固化涂层组合物总重量的约0.1%至约15%。在一些实施方案中,光引发剂的含量为可固化涂层组合物总重量的约1%至约10%。在一些实施方案中,光引发剂的含量为可固化涂层组合物总重量的约3%。
合适的氨基甲酸酯预聚物包括具有聚酯或聚醚主链的含氨基甲酸酯的低聚物。在一些实施方案中,氨基甲酸酯预聚物还包含一个或多个丙烯酸酯或甲基丙烯酸酯基团或另一个或多个可与丙烯酸酯或甲基丙烯酸酯单体反应的基团。因此,在一些实施方案中,氨基甲酸酯预聚物是多官能的。在一些实施方案中,氨基甲酸酯预聚物是二或三官能的(例如,是二或三丙烯酸酯)。在一些实施方案中,氨基甲酸酯预聚物是聚醚氨基甲酸酯二丙烯酸酯。合适的氨基甲酸酯预聚物包括但不限于Miramer PU2510(Miwon Specialty Chemical有限公司,韩国龙仁市)和Sartomer CN980(Sartomer Americas,Exton,美国宾夕法尼亚州)。在一些实施方案中,基于可固化涂层组合物的总重量计,氨基甲酸酯预聚物的含量为约10重量%至约25重量%。在一些实施方案中,基于可固化涂层组合物的总重量计,氨基甲酸酯预聚物的含量为约15重量%至约20重量%(例如,约15、16、17、18、19或约20重量%)。
合适的交联剂包括多官能丙烯酸酯化合物,例如含有三个或更多个丙烯酸酯或甲基丙烯酸酯基团的那些交联剂。在一些实施方案中,交联剂是多元醇的聚丙烯酸酯化或甲基丙烯酸酯化产物(即,多元醇与丙烯酸或甲基丙烯酸酯化形成的产物)。合适的交联剂包括但不限于二季戊四醇、三羟甲基丙烷三丙烯酸酯、三羟甲基丙烷三甲基丙烯酸酯、三羟甲基丙烷(EO)3三丙烯酸酯、季戊四醇三丙烯酸酯和季戊四醇四丙烯酸酯。在一些实施方案中,交联剂包含聚二季戊四醇六丙烯酸酯(DPHPA)或由其组成。在一些实施方案中,基于可固化涂层的总重量计,交联剂的含量为约2重量%至约15重量%。在一些实施方案中,基于可固化涂层的总重量计,交联剂的含量为约2重量%至约10重量%。在一些实施方案中,基于可固化涂层的总重量计,交联剂的含量为约4重量%至约8重量%。在一些实施方案中,基于可固化涂层的总重量计,交联剂的含量为约5重量%至约7重量%。
在一些实施方案中,硫醇单体可以作为链转移剂包含在涂层中,例如以加速自由基固化。合适的硫醇单体包括例如但不限于季戊四醇四(3-巯基丁酸酯),Showa DenkoK.K.(日本东京)以商品名KARENZ MTTM PE1出售。
可以使用任何合适的增粘剂或促进剂。合适的增粘剂包括具有可参与聚合/固化反应的基团(例如自由基固化反应)和粘附到金属或其他类型基材的基团的化合物,可固化组合物可用于绝缘所述其他类型的基材。参与固化反应的基团可以是(例如)乙烯基、(甲基)丙烯酸酯或硫醇。附着到金属上的基团包括羟基、酸(例如,羧酸、磷酸或磺酸)、磷酸盐、锆酸盐、钛酸盐和硅烷。因此,增粘剂包括但不限于(甲基)丙烯酸酯官能化的羧酸或磷酸。示例性的合适的增粘剂包括(甲基)丙烯酸羟乙酯、(甲基)丙烯酸羟丙酯、二或三烷氧基锆酸酯或钛酸酯、乙烯基三甲氧基硅烷、巯基丙基三甲氧基硅烷、异氰基烷基三烷氧基硅烷、甲基丙烯酰基烷基三烷氧基硅烷、氨基烷基三烷氧基硅烷和环氧烷基三烷氧基硅烷。另一种合适的硅烷增粘剂是乙烯基三甲氧基硅烷。也可以使用巯基硅烷,例如巯基丙基三甲氧基硅烷和巯基丙基三乙氧基硅烷。合适的增粘剂的其他例子包括丙烯酸和甲基丙烯酸(MAA)。在一些实施方案中,一种或多种增粘剂包括甲基丙烯酸缩水甘油酯、2-羟乙基甲基丙烯酸磷酸盐(HEMA磷酸盐)、MAA和环氧硅烷中的一种或多种。在一些实施方案中,环氧硅烷是γ-缩水甘油氧基丙基三甲氧基硅烷(以商品名SILQUEST A-187TM出售,MomentivePerformance Materials,美国纽约沃特福德)。
在一些实施方案中,一种或多种增粘剂的含量为约0.1重量%至约15重量%。在一些实施方案中,一种或多种增粘剂的含量为约2重量%至约6重量%。
在一些实施方案中,可固化涂层还可包括一种或多种添加剂,例如但不限于除酸剂、着色剂或消泡剂。例如,在一些实施方案中,一种或多种添加剂包括除酸剂。在一些实施方案中,除酸剂包含磷酸锌(例如来自Heubach GmbH(德国朗格尔斯海姆)的ZPA)、氧化锌和/或钼酸锌(例如来自Kukuchi Color and Chemicals Corporation(日本东京)的LF Bowsei M-PSN)。在一些实施方案中,除酸剂包含磷酸锌或由磷酸锌组成。
在一些实施方案中,可固化涂层还包括一种或多种填料。合适的填料包括但不限于气相二氧化硅(例如,经处理的疏水性或未处理的亲水性气相二氧化硅(例如以商品名CAB-O-SILTM出售的那些,Cabot Corporation,美国马萨诸塞州波士顿))和霞石正长岩。因此,在一些实施方案中,填料包含未经处理的亲水气相二氧化硅、经处理的疏水二氧化硅和/或霞石正长岩或由未经处理的亲水气相二氧化硅、经处理的疏水二氧化硅和/或霞石正长岩组成。
可以使用任何合适的技术,例如喷涂、辊涂或浸涂,将可固化涂层涂覆在目的基材(例如金属或复合基材的表面)上。在一些实施方案中,使用喷涂将可固化涂层涂覆在基材上。在一些实施方案中,可固化涂层在基材上的涂布厚度可为约25微米至约200微米(例如,约25、30、35、40、45、50、55、60、65、70、75、80、85、90、95、100、105、110、115、120、130、140、150、175或约200微米)。在一些实施方案中,可固化涂层具有约80微米至约125微米的厚度。可固化涂层的固化可以通过将可固化涂层暴露于UV或可见光辐射来进行。在一些实施方案中,使用汞灯(例如,使用1500mJ/cm2的能量)将可固化涂层暴露于UV辐射。
在一些实施方案中,可固化涂层是100%固体涂层,如本文所用,其是指固化前与涂层后具有基本相同厚度的涂层。在一些实施方案中,固化涂层没有针孔、气泡并且包括对其所涂覆的基材(例如,电池组组件)的良好边缘覆盖。
在一些实施方案中,本发明公开的可固化涂层固化形成介电涂层,该介电涂层使得其所施加到的基材(例如电池组的组件)电绝缘。由于该化学物质是紫外线固化的,因此它可以在几秒钟内进行喷涂、辊涂、浸渍和固化,从而确保它是一种具有成本效益的制造通常大批量生产的电池组电池的方法。与通过压敏胶带粘附的PET膜不同,本发明的UV固化涂层与电池组件的表面化学键合,提供更好的粘附性,因此降低了热阻抗的威胁,同时提供了相似或更好的介电性能。此外,本发明的涂层提供了周围的化学物质,例如作为热间隙填料的化学物质,以更牢固地结合到UV固化涂层,还降低或消除了分层的风险,并使不同材料层之间的热阻抗威胁最小化.
因此,本发明公开的主题的可UV固化的涂层具有若干优点,特别是当用于绝缘和保护电池组组件时。例如,单组分(1K)100%固体涂层可以喷涂,并为涂层部件提供良好的边缘覆盖,在潮湿条件下老化后具有良好的附着力(85℃、85%RH,100、250、500或1000小时)。在一些实施方案中,固化涂层在85℃和85%相对湿度下老化最长达1000小时后保持粘附性(例如,根据ISO 2409具有平均1级附着力)。此外,本发明实施方案的涂层提供良好的电压击穿保护。在一些实施方案中,固化涂层在约100微米厚度时具有约5千伏(kV)至约10kV的击穿电压。在一些实施方案中,固化涂层在约100微米厚度时具有约8kV至约10kV的击穿电压。下面的表1总结了与PET膜相比,由本发明公开的可UV固化的涂层形成的UV介电涂层的示例性优势。
表1.UV介电涂层和PET膜的比较
PET膜 | UV介电涂层 | |
功能 | 介电保护 | 介电保护 |
粘合方法 | 压敏粘合剂(润湿和范德华) | 共价化学键 |
粘合强度 | 低 | 高 |
形成 | 固体膜 | 液体 |
施加方法 | 压力辊 | 喷涂、浸涂或辊涂 |
固化方法 | 无 | 快速紫外引发自由基聚合 |
在一些实施方案中,本文公开的主题提供涂有介电涂层的层的基材,其中该介电涂层是通过固化(例如,UV固化)本发明公开的可固化涂层的层的反应产物。在一些实施方案中,基材是金属基材或复合基材。在一些实施方案中,经涂覆的基材是电池组电池或其他电池组件(例如,电池组件的一部分,例如用于电动车辆中)。
例如,在一些实施方案中,可将可UV固化的涂层涂覆到电池组电池外表面的至少一侧上以提供经涂覆的电池组电池。在一些实施方案中,经涂覆的电池组电池是电池组电池组件或电池组的一部分。例如,图1说明了在两个电池组电池之间使用本发明公开的介电涂层(例如,代替PET膜)绝缘的电池组电池组件界面100。在电池组电池组件界面100中,第一电池组电池基材102(例如,铝或另一种金属或复合材料)涂覆有介电涂层104,该介电涂层104作为本发明公开主题的可UV固化的涂层的反应产物形成。第二电池组电池基材102'涂有介电涂层104',该介电涂层104'也作为本发明公开主题的可UV固化的涂层的反应产物形成。设置在两个介电涂层涂覆的电池组电池基材之间的是热管理粘合剂/灌封材料层106。
在一些实施方案中,涂覆有本发明公开的涂层的基材是在涂层被施加和固化后可用于形成电池组电池的一部分的材料。例如,在一些实施方案中,所述基材是金属(例如,Al)线圈。
在一些实施方案中,介电涂层的层厚度在约25微米和约200微米之间。在一些实施方案中,介电涂层具有约80微米至约125微米的厚度。在一些实施方案中,介电涂层的层在潮湿或干燥条件下(例如在85℃和85%相对湿度)老化长达1000小时后保持粘附性(例如,具有根据ISO 2409的平均1级附着力)。在一些实施方案中,介电涂层在约100微米厚度时具有约5kV至约10kV的击穿电压。在一些实施方案中,介电涂层在约100微米时具有约8kV至约10kV的击穿电压。
在一些实施方案中,本发明公开的主题提供了一种用介电涂层涂覆基材的方法。在一些实施方案中,该方法包括施加本发明公开的可固化涂层(例如,可UV固化的涂层,其包含一种或多种丙烯酸酯单体、光引发剂、氨基甲酸酯预聚物、交联剂、一种或多种增粘剂,以及任选的一种或多种更多填料和/或一种或多种添加剂)的层到基材表面;以及将可固化涂层暴露于紫外线辐射,从而形成经涂覆的基材。在一些实施方案中,基材包括金属表面。例如,金属可以是铝或钢。在一些实施方案中,基材包括电池组电池或电池组的组件。或者,在一些实施方案中,基材可以是旨在用于生产电池组件的材料。例如,基材可以包括金属片或线圈(例如,Al线圈)。因此,在一些实施方案中,该方法可进一步包括由经涂覆的基材形成电池组件。
可固化涂层的层可以通过任何合适的技术施加。在一些实施方案中,通过喷涂、辊涂或浸涂进行施加。在一些实施方案中,施加是通过喷涂进行的。在一些实施方案中,可固化涂层的层厚度为约25微米至约200微米(例如,约25、30、35、40、45、50、55、60、65、70、75、80、85、90、95、100、105、110、115、120、125、130、140、150、160、175或约200微米)。在一些实施方案中,可固化涂层的层具有约80微米至约125微米的厚度。在一些实施方案中,由汞灯提供UV辐射。
实施例
包括以下实施例以进一步说明本发明公开的主题的各种实施方案。然而,根据本发明的公开内容,本领域的普通技术人员应该理解,在不脱离本发明公开主题的精神和范围的情况下,可以对所公开的具体实施方案进行许多改变并且仍然获得相似或类似的结果。
根据下表2中描述的配方制备可固化涂层,并将其喷涂到来自Q-Lab Corporation(美国俄亥俄州韦斯特莱克)的铝基材(3003)上以进行测试。涂层以80微米至125微米(μm)的膜厚施加,如用Fischer示波器模型dualscope FMP40C(Fisher Technology Inc.,美国康涅狄格州温莎)测得的。然后用辐射计(例如以商品名UVICURE Plus II(EIT,斯特林,弗吉尼亚州,美国)出售的辐射计)以1500毫焦耳/平方厘米(mJ/cm2)的汞灯(H+灯泡)固化涂层)。
观察到所得固化涂层没有针孔、无气泡并具有非常好的边缘覆盖。测定了涂层的其他性能并将其报告在下表2中。为进行比较测定了标准PET膜的相同性能。
表2.涂层配方和固化涂层的性能。
应当理解,可以改变本发明公开的主题的各种细节而不脱离本发明公开的主题的范围。此外,以上描述仅用于说明而非限制目的。
Claims (24)
1.一种可固化涂层,包含一种或多种丙烯酸酯单体、光引发剂、氨基甲酸酯预聚物、交联剂、一种或多种增粘剂和任选的一种或多种填料和/或一种或多种添加剂。
2.根据权利要求1所述的可固化涂层,其中所述一种或多种丙烯酸酯单体包含反应性稀释剂。
3.根据权利要求2所述的可固化涂层,其中所述反应性稀释剂包括丙烯酸异冰片酯、丙烯酸异辛酯和甲基丙烯酸甲酯(MMA)中的至少一种。
4.根据权利要求1至3中任一项所述的可固化涂层,其中所述光引发剂包括UV活化的光引发剂。
5.根据权利要求1至4中任一项所述的可固化涂层,其中所述氨基甲酸酯预聚物包含聚醚氨基甲酸酯二丙烯酸酯。
6.根据权利要求1至5中任一项所述的可固化涂层,其中所述交联剂包括聚二季戊四醇六丙烯酸酯(DPHPA)。
7.根据权利要求1至6中任一项所述的可固化涂层,其中所述一种或多种增粘剂包括甲基丙烯酸缩水甘油酯、甲基丙烯酸2-羟乙酯(HEMA)磷酸酯、环氧硅烷和甲基丙烯酸(MAA)中的至少一种。
8.根据权利要求1至7中任一项所述的可固化涂层,还包括除酸剂。
9.根据权利要求8所述的可固化涂层,其中所述除酸剂选自由磷酸锌、氧化锌和钼酸锌组成的组。
10.根据权利要求1至9中任一项所述的可固化涂层,包括一种或多种填料。
11.根据权利要求10所述的可固化涂层,其中所述一种或多种填料包括未处理的亲水气相二氧化硅、经处理的疏水气相二氧化硅和/或霞石正长岩。
12.根据权利要求1至11中任一项所述的可固化涂层,其中所述涂层是100%固体涂层。
13.根据权利要求1至12中任一项所述的可固化涂层,其中固化涂层在约100微米厚度时具有约5千伏(kV)至约10kV的击穿电压。
14.根据权利要求1至13中任一项所述的可固化涂层,其中所述固化涂层在85℃和85%相对湿度下老化至多1000小时后仍保持粘性。
15.根据权利要求1至14中任一项所述的可固化涂层,其中所述固化涂层没有针孔、气泡并且包括良好的边缘覆盖。
16.一种涂有介电涂层的层的电池组电池或其他电池组件,其中所述介电涂层是通过固化根据权利要求1至15中任一项所述的可固化涂层的层而形成的反应产物。
17.根据权利要求16所述的电池组电池或其他电池组件,其中所述介电涂层的层具有约25微米至约200微米的厚度。
18.一种用介电涂层涂覆基材的方法,该方法包括将根据权利要求1至15中任一项所述的可固化涂层的层施加到基材表面上;以及将所述可固化涂层暴露于紫外线辐射,从而形成经涂覆的基材。
19.根据权利要求18所述的方法,其中所述基材包括金属表面,任选地其中所述金属是铝。
20.根据权利要求19所述的方法,其中所述基材包括电池组电池或电池组的组件。
21.根据权利要求19所述的方法,还包括由所述经涂覆的基材形成电池组件。
22.根据权利要求18至21中任一项所述的方法,其中通过喷涂、辊涂或浸涂来施加可固化涂层的层。
23.根据权利要求18至22中任一项所述的方法,其中所述可固化涂层的层的厚度为约25微米至约200微米。
24.根据权利要求18至23中任一项所述的方法,其中由汞灯提供UV辐射。
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