JP2001519282A - Insulated heat sensitive material - Google Patents

Abstract

(57) Abstract: A) heat-sensitive members; and B) porous or continuous, evacuated to an absolute pressure of less than about 10 Torr, sealed, and covering more than about 20% of the surface area of said members. A core stock made of one or more hard substance matrices of gas bubbles, wherein said core stock is optionally placed in an evacuated cavity of said member; or C) to an absolute pressure of less than about 10 Torr A deformable receptacle that is evacuated, sealed, surrounds a core stock made of one or more rigid or porous cell matrixes, and covers about 20% or more of the surface area of the member Wherein the core stock or the evacuated panel has an R value of 10 or more per inch. Las, heat-sensitive member and the engine compartment that is insulated.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001] The present invention relates to an insulated heat sensitive component.
t), and an engine compartment containing an insulated heat sensitive member. BACKGROUND OF THE INVENTION Engine compartments of vehicles (e.g., automobiles) generate a significant amount of heat when operating or during cool down. Sources of heat include the internal combustion of diesel engines, exhaust manifolds, and catalytic converters.

[0002] Certain automotive components are extremely sensitive to heat. Typical heat-sensitive components include batteries, power distribution centers,
There are relay enclosures, fuse boxes, computers, and communication equipment. The battery supplies electricity or power to start the vehicle, while the power distribution center uses power from the battery and / or the alternator to transfer electricity to other electrical components (eg, spark plugs and / or glow plugs, radios or entertainment Center, light source, heater, antenna, air conditioner, instrument panel, lock, window, etc.).

[0003] A conventional lead-acid battery has a problem that when the electrolyte temperature in the battery exceeds about 60 ° C,
The charging performance decreases rapidly. The rate of chemical reaction between lead and acid doubles at temperatures above about 60 ° C. for every temperature increase of about 10 ° C. The resulting lead salts collect as deposits on the bottoms of the battery cells and the bridge plate, causing an electrical short circuit in the battery. Prolonged and / or repeated exposure to such temperature levels causes such batteries to prematurely lose their ability to generate electricity. Battery failures occur too quickly, increasing the warranty costs for car manufacturers.

[0004] The problem of excessive heat exposure has led to recent vehicle styling, lower hood lines from an aerodynamic point of view, and a more enclosed structure in the engine compartment. It is getting worse by being. All of this is intertwined, resulting in tighter packing of automotive components, reduced engine compartment space, and reduced grill open space. The dense packing causes a rise in the temperature in the engine compartment (typically above 150 ° C. around the engine and exhaust manifold). Tight packing and reduced grill space further exacerbate cooling air flow and emissions within the engine compartment.

[0005] Temperatures that are too high can occur when the vehicle is running, idling, or during cool down. The highest temperature is best observed during cool down. This is because the engine is still emitting heat, but the engine compartment is usually not cooled by a fan or vent air.
During cool down, especially in a warm or hot climate, the battery electrolyte temperature often reaches 70 ° C. or higher or 90 ° C. or higher.

[0006] Attempts to solve the problem of batteries being subjected to excessive thermal exposure have been unsuccessful. According to the technology used, additional piping and additional fans were used to direct the exhaust air towards the battery, or the battery could be relocated to another compartment or outside the engine compartment. Or insulates the battery with plastic moldings or closed cell foam of cross-linked polyvinyl chloride. The use of additional pipelines or fans is costly, uses additional space, and reduces cool-down effectiveness. Battery relocation is costly and creates safety issues. The use of plastic moldings as shields is somewhat effective, but consumes too much space. The use of polyvinyl chloride foam (known in the industry as "huggies") generally reduces the temperature of the battery electrolyte by about 10 ° C or less, and the problem is only partially eliminated.

There is a need for a means to better insulate the heat sensitive members of the vehicle to prevent the engine compartment from becoming hot. Such measures replace as little volume or space as possible in the engine compartment. SUMMARY OF THE INVENTION The present invention comprises: a) a heat-sensitive member; and B) a porous or evacuated, sealed, and covering at least about 20% of the surface area of the member to an absolute pressure of about 10 Torr or less. A core stock made of one or more rigid substance matrices of open cells, wherein said core stock is optionally placed in an evacuated cavity of said member; or C) to an absolute pressure of about 10 Torr or less. Deformable, sealed, surrounds a core stock made of one or more hard material matrices, porous or open-cell, and deformable, covering about 20% or more of the surface area of the member An evacuated panel containing a receptacle, wherein said core stock or evacuated panel is 10 or more per inch. An engine compartment providing an R value.

[0008] The invention further comprises: A) a heat-sensitive member; and B) a porous, evacuated, sealed to an absolute pressure of about 10 Torr or less, and covering about 20% or more of the surface area of said member. Or a core stock made of one or more rigid substance matrices of open cells, wherein said core stock is optionally placed in an evacuated cavity of said member; or C) an absolute pressure of less than about 10 Torr Evacuated, sealed, surrounding a core stock made of one or more hard material matrices, porous or open-cell, and deformable, covering about 20% or more of the surface area of the member Evacuated panel containing a receptacle, wherein said core stock or evacuated panel is 1 / inch. Thermal sensitive member insulated bring R value of more.

[0009] The insulated heat-sensitive member may be a small or miniaturized member used as part of a larger assembly (eg, a vehicle) (eg, as part of an engine compartment). While the primary application of the present invention is to insulate heat sensitive members from excessive heat ingress from environments that experience higher heat, other aspects of the invention include retaining heat or heat loss or heat gain. To stabilize the environment of the member.

[0010] Various heat sensitive components (eg, insulated batteries, power distribution centers,
Insulated automotive components, such as fuse panels, relay enclosures, computers, or communications equipment) can be protected by the present invention. Of particular interest are batteries, computers, and communications equipment. A particularly useful embodiment is an insulated automotive battery when the component is a lead acid battery and the engine compartment is an automotive engine compartment. The battery may have an evacuated insulation panel inside or outside the battery, or may have the foam disposed within an evacuated cavity in the battery. In one or more aspects of the invention, it is preferred to use a vented panel (also known as a vented or vacuum insulated panel (VIP)) to slow down the heat flow. DETAILED DESCRIPTION OF THE INVENTION The present invention is particularly well suited for heat sensitive components, where weight and size considerations are important, for example, when the environment in the engine compartment during vehicle operation is extremely harsh and constantly changing. It provides a solution to the problem of maintaining a stable environment for vehicle components when awake.

[0011] In one embodiment of the invention, a core stock made of one or more hard material matrices, porous or open-celled, extends in at least one dimension across the surface of the hard material matrix. One or more recesses therein, the outer surface of the evacuated cavity of the receptacle or member substantially conforms to the shape of the core stock and the recesses therein, and the final panel is substantially wrinkled. And optionally including one or more rigid plates having an unsurfaced surface, optionally having one or more depressions, disposed adjacent the major surface of the core stock.

Suitable materials for the hard material matrix of the core stock include open-cell thermoplastic foams, polycarbonate foams, thermoset foams, polyurethane foams, epoxy resin foams, formaldehyde foams, phenolic foams, isocyanurate foams, It is silica, glass fiber, glass beads, airgel, or xerogel. Preferred matrix materials include about 70
There are alkenyl aromatic polymer foams having an average cell size of less than micrometers, propylene polymer foams, extruded foams composed of agglomerate strands, an open channel foam, or perforated foams.

[0013] Alternative embodiments of this aspect of the invention [US patent application Ser. No. 08 / 993,536, filed Dec. 18, 1997 and the associated PCT case filed Sep. 16, 1998, which are incorporated herein by reference. The subject matter of which is incorporated herein by reference) is an evacuated insulation having a core stock of a porous or open-celled hard material matrix (eg, an open-celled alkenyl aromatic polymer foam) The problem of wrinkling on the surface of the panel has been solved by supplying a core stock having recesses therein. As the core stock shrinks due to exhaust and / or exposure to high temperatures, the deformable receptacle or enclosure surrounding the core stock deforms into the contracted core stock. These depressions provide extra surface area for the receptacle to deform or conform. Without these depressions, wrinkles will form in the receptacle when the core stock shrinks. The present invention greatly improves the aesthetic appearance and the physical appearance of the panel. A further advantage is a reduced evacuation time.

[0014] Preferably, one or both of the one or more hard substance matrix, porous or open cell, and the one or more plates have a plurality of depressions. The cavities need to extend in at least one dimension orthogonal to the surface of the material matrix, while the cavities may be one or both of one or more of a porous or open-celled hard material matrix and one or more plates. Are preferably spread in two dimensions so that the surfaces are orthogonal to each other. In one embodiment, the matrix is cross-shaped, such that one or more of the porous or open-cell one or more rigid material matrices and one or more of the plates have substantially all surfaces orthogonal to each other. It has depressions in a square or diagonal pattern. In other embodiments,
The matrix may be in a dimple pattern, with one or more hard material matrix, porous or open cell, and one or more plates, or substantially all surfaces, orthogonal to all surfaces. Has depressions. The indentations are typically no more than about 3.2 mm in depth and no more than about 3.2 mm in width, but may be larger for certain core stocks.

The depressions in the surface of the matrix can be of various shapes (eg, dimples, grooves,
Or a trough). The depressions may take a regular pattern with the surfaces orthogonal to each other, or may take an irregular pattern. The depressions may traverse or extend the surface continuously or discontinuously orthogonally. The depressions extend in two dimensions with the surface of the matrix orthogonal. Preferably, the indentations generally extend from one end of the matrix to another. If the depressions take the form of dimples, the depressions are preferably provided at regular intervals so that substantially all surfaces of the matrix are orthogonal. If the depressions take the form of grooves or troughs, the depressions preferably intersect at right angles to the surface as they traverse or extend.

The indentation is at a depth and presence such that when the core stock shrinks, the deformable receptacle leans against the surface of the matrix and the indentation in the matrix, and the surface of the receptacle is substantially wrinkled. It is preferably provided with such a depth and existing state. In other words, the additional core stock surface area obtained by the depression after shrinkage of the core stock preferably approximately corresponds to the total surface area of the core stock that would be lost due to shrinkage. The indentations may be at any depth or width within the core stock, but not more than about 1/8 inch (3.2 millimeters) deep, and not more than about 1/8 inch (3.2 millimeters). It preferably has a width of

[0017] The depressions can be imprinted in the core stock by any means known in the art. For example, (a) passing the foam through a set of opposed embossing rollers having a desired groove pattern such as ridges; (b) engraving using an opposing plate having the desired groove pattern such as ridges. (C) engrave the desired pattern using a series of wires placed adjacent to the core stock; (d) use a knife, saw, router, or water spray to create the desired pattern in the core stock. Means include cutting the pattern; and (e) melting the desired pattern in the core stock using a hot wire or other heat source. In cases (a) and (b), momentary embossing by ridges is usually sufficient for permanent indentation, but for other reasons when core stock is pressed. It is desirable that the stamping be performed for a longer time.

The present invention is directed to the manufacture of any vacuum insulated panel using a core stock that shrinks when exposed to atmospheric pressure or high temperature while enclosed in a barrier pouch or receptacle. Useful for Examples of suitable core stock materials for use in the present invention include polystyrene foam; open-cell thermoplastic foams such as polypropylene foam, preferably US Pat. No. 5,527,573, which is incorporated herein by reference. Polycarbonate foams; thermosetting foams such as polyurethane foams, epoxy resin foams, formaldehyde foams, phenolic foams, or isocyanurate foams; or air or gas from air bubbles prior to encapsulation. Thermoplastic or thermoset other polymeric materials having an open cell structure that allows the removal of Another material generally useful as a core stock material in the manufacture of vacuum insulation panels is a panel filled with silica or other powder, provided that the loose powder is sufficiently compressed or bonded in some manner. Should form such an integral structure and then be scored to provide a smooth surface after evacuation. The present invention is further applicable to compressed fiberglass or glass bead panels if the core is sufficiently rigid to allow the surface to be scored, and to exhibit shrinkage when encapsulated in VIP. It can also be applied to aerogels and xerogels. Preferred core stock materials are polystyrene and polypropylene foams, particularly preferred are polystyrene foams.

It is believed that the present invention can be practiced by placing one or more rigid plates having depressions on one or more surfaces of the foam in the evacuated insulation panel. The depressions can take the shape, pattern, and dimensions as described above for depressions in the foam. The panels can be assembled as described above, except that one or more plates are inserted into the deformable receptacle with the foam. For a typical rectangular or square panel, the plates are usually located on the two major surfaces of the foam. The plate can be made of any natural or synthetic material (such as metal, wood, or metal) that is chemically inert to the core stock and receptacle, as long as the material used is rigid enough to resist deformation during the evacuation operation. Plastics). As the panel is evacuated and the foam contracts, the deformable receptacle conforms to the shape of the foam and leans substantially within the recess of the plate. Use of the plate inside or outside the VIP to shield the low melting core stock from temporary thermal exposure (eg, during foaming of polyurethane foam around the VIP during appliance assembly). Can be.

The present invention provides a solution to the problem of insulating or isolating automotive components (eg, batteries) by placing the evacuated open cell foam adjacent to the exterior of the component or battery. The evacuated open cell foam is
Provides sufficient insulation capacity while occupying the minimum required volume.

In a preferred embodiment where the core stock is a foam, typical foams, when evacuated, have an "R value" of about 10 or more (preferably about 15 or more, most preferably about 20 or more) ( That is, the thermal resistance per inch of thickness) is shown. “
R value "is the reciprocal of the thermal conductivity of the foam as measured in units of BTU in./hr.ft ^2. ° F. For ^{example, 0.1BTU in./hr.ft 2. ° F (} 0 The exhaust foam having a thermal conductivity of 0.0144 watts / meter K) has an R value of 10. These R values are the initial R values, not the R values after aging.

A conventional automobile battery takes the form of a rectangular or square box or case, with an anode and a cathode protruding. Conventional batteries have a top panel, a bottom panel, and four side panels. The exposed surface area of a conventional battery is in the form of these panels.

In the present invention, the evacuated foam preferably covers at least about 20%, and most preferably at least about 50%, of the outer surface area of the automotive battery. The extent to which the outer surface is occupied will vary greatly depending on the expected maximum temperature to which the battery will be exposed and how much thermal protection is required. The foam may take the form of an exhaust insulation panel that can be placed adjacent to or near the outer surface. The panel may be located outside or inside the battery. Alternatively, such panels could be formed into an insulated box or blanket in which to place or house the battery. If desired
The panel may be covered with cushioning material or a rigid facer to protect the physical integrity and airtightness of the panel. Alternatively, the foam may be placed in an evacuated cavity inside the battery, forming the equivalent of an exhaust panel in the battery. Instead of being located on all or most of the surface of the battery, the panel may be located only adjacent or adjacent to the outer surface that is directly exposed to radiant heat generated in the engine compartment. The outer surface of the battery that is not directly exposed to radiant heat may or may not be covered by a panel. If desired, some outer surface areas may be left uncovered to allow dissipation of heat generated in or absorbed by the battery during operation of the vehicle.

The battery can be of any known type that is sensitive to very high use temperatures. Useful batteries include, but are not limited to, batteries utilizing lead / acid chemistry and lithium metal halide chemistry.

The engine compartment containing the insulated battery is shown in FIGS. In FIG. 1, the engine compartment 10 includes a battery 14 and an engine 18. In FIG. 2, the engine compartment 20 comprises insulated batteries 22 and 24 and an engine 28.
Contains.

An embodiment of an insulated battery is shown in FIGS. In FIG. 3, the insulated battery 30 includes a front surface 36, a top surface 38, a back surface 40, a bottom surface 42, and sides 44 and 46. An anode 32 and a cathode 34 protrude from the front surface 36. An evacuated panel 48 is positioned adjacent to surfaces 36, 40, 44, and 46 to provide a snug or tight coverage of some or all of the exposed surface. Panels 48 covering surfaces 40, 44, and 46 are connected at a panel interface 47 to form a foldable pouch 49 having interconnected but separate vented foams. In FIG. 4, the insulated battery 5
0 includes a front surface 52, a top surface 54, a back surface 56, a bottom surface 52, and side surfaces 58 and 60. An anode 62 and a cathode 64 protrude from the front surface 52. The evacuated panel 66 is used to cover the exposed surface closely or tightly.
Are located adjacent to surfaces 52, 58, and 60.

[0027] The foam has an open cell content of about 50% or more (according to ASTM 2856-A), preferably has an open cell content of about 70%, and more preferably has an open cell content of about 90% or more. It is preferred and most preferably has an open cell content of about 95% or more.

The foam may have any cell size, but preferably has a fine cell size in order to obtain better heat insulating performance. Cell size or pore size is measured according to ASTM D3576-77. However, at this time,
Rather than taking measurements directly from the foam, the measurements are taken from magnified photographs obtained with a scanning electron microscope.

[0029] The microcellular foam has an average cell size of about 70 microns or less, preferably has an average cell size of about 5 to about 30 micrometers, and has an average cell size of about 1 to about 30 micrometers. Is more preferred.

Preferably, the foam has a density (according to ASTM D-1622-88) of from about 16 to about 250 kg / m ³ , most preferably from about 25 to about 100 kg / m ³ .

An evacuated foam is a foam that has a partial or near full vacuum of absolute pressure below atmospheric pressure in its cells. Preferably, the evacuated foam has an absolute pressure of less than about 10 Torr, more preferably has an absolute pressure of less than about 1 Torr, and most preferably has an absolute pressure of less than about 0.1 Torr.

The evacuated panel receptacle or enclosure can be any of those known in the art. One embodiment of an evacuated panel uses a receptacle or enclosure formed of a laminate sheet that includes three or more layers. The outer layer includes a scratch resistant material such as polyester or nylon. The inner layer includes a barrier material such as aluminum, polyvinylidene chloride, or polyvinyl alcohol. The barrier material may be in the form of a separately applied foil or film or, in the case of metal, by evaporation. The inner layer comprises a heat-sealable material (eg, polyethylene, ethylene / acrylic acid copolymer, etc.). Further findings are described in U.S. Patent Nos. 5,346,928 and 5,627,219, which are incorporated herein by reference.

It is preferred to incorporate an infrared attenuating agent (IAA) into the foam. The IAA may be an infrared reflective material, an infrared absorbing material, or both. IAAs are composed of a different material than the material incorporated in the foam. Useful IAAs include particulate flakes of metal (eg, aluminum, silver, and gold), and carbonaceous materials (eg, carbon black,
Activated carbon black, and graphite). Useful carbon blacks include thermal black, furnace black, acetylene black, and gas black. Useful graphites are natural graphite and synthetic graphite. Preferred IAAs are carbon black and graphite. The IAA is preferably from about 1.0 to about 20% by weight, more preferably from about 4.0 to about 20% by weight, and most preferably from about 4.0 to about 10.0% by weight based on the weight of the polymeric material. Make up 0% by weight. Substantial infrared attenuation occurs at about 4% to about 40%, based on the weight of the polymeric material. In the case of carbon black and graphite, it is desirable to use particles of a size such that a high degree of dispersion in the foam is achieved.

[0034] The foam can be compressed to about 40 to about 90% of its initial thickness or volume to increase the insulation capacity per unit thickness. Compression foam is WO97 / 27986
And the patent literature is incorporated herein by reference.

The foam of the present invention may be comprised of any known organic or inorganic material known to be useful in making open cell foams. Useful materials include thermoplastic polymers, thermoset polymers, airgels, ceramics, and glasses. Useful thermoplastic polymers include ethylene polymers and alkenyl aromatic polymers. Useful ethylene polymers include polyethylenes such as low density polyethylene. Useful thermosetting polymers include:
There are polyisocyanurates, polyurethanes, and phenolic resins.

Useful foams include alkenyl aromatic polymer materials. Suitable alkenyl aromatic polymer materials include alkenyl aromatic homopolymers and copolymers of alkenyl aromatic compounds with ethylenically unsaturated comonomers copolymerizable with the alkenyl aromatic compound. The alkenyl aromatic polymer material may further comprise less than half the non-alkenyl aromatic polymer. The alkenyl aromatic polymer material may be composed of only one or more alkenyl aromatic homopolymers, may be composed of only one or more alkenyl aromatic copolymers, or may be composed of each alkenyl aromatic homopolymer. May be composed solely of a blend of at least one of the above and one or more of the respective alkenyl aromatic copolymers, or may be composed solely of a blend of any of these substances and a non-alkenyl aromatic polymer. . The alkenyl aromatic polymer material, regardless of composition, contains at least 50% by weight, and preferably at least 70% by weight, of alkenyl aromatic monomer units. Most preferably, the alkenyl aromatic polymer material is composed entirely of alkenyl aromatic monomer units.

Suitable alkenyl aromatic polymers include those derived from alkenyl aromatic compounds such as styrene, α-methylstyrene, ethylstyrene, vinylbenzene, vinyltoluene, chlorostyrene, and bromostyrene. The preferred alkenyl aromatic polymer is polystyrene. Small amounts of monoethylenically unsaturated compounds (eg, C _2-6 alkyl acids and alkyl esters, ionomer derivatives, and C _4-6 dienes) can be copolymerized with alkenyl aromatic compounds. Examples of the copolymerizable compound include acrylic acid, methacrylic acid, ethacrylic acid, maleic acid, itaconic acid, acrylonitrile, maleic anhydride, methyl acrylate, ethyl acrylate, isobutyl acrylate, n-butyl acrylate, and methacrylic acid. Examples include methyl acid, vinyl acetate, and butadiene.
Preferably, the foam is substantially (ie, greater than or equal to 70% by weight) polystyrene, and most preferably is entirely composed of polystyrene. The alkenyl aromatic polymer foam preferably does not contain rubbers such as C _4-6 dienes and thermosetting polymers such as polyisocyanurates and polyurethanes.

[0038] Useful microcellular foams are open-cell alkenyl aromatic polymer extruded foams. The open cell foam is greater than 50% by weight (preferably about 70%
And alkenyl aromatic polymer materials containing alkenyl aromatic monomer units. This foam may be composed entirely of polystyrene. The form is
Having an open cell content of about 50% or more (according to ASTM 2856-A),
Preferably, it has an open cell content of above, and most preferably, has an open cell content of about 95% or more. The foam has an average cell size of less than or equal to about 70 micrometers (measured according to ASTM D3576-77 except that the foam is not measured directly but measured by scanning electron microscopy);
Preferably, it has an average cell size of about 1 to about 30 micrometers, and most preferably, it has an average cell size of about 5 to about 30 micrometers. Foams are particularly useful in vacuum insulation panels. Explanation about the manufacturing method,
It is described below and in WO 96/34038, which is incorporated herein by reference.

[0039] Micro-open cell extruded foams are formed by heating a thermoplastic material into a plasticized or molten polymer material, introducing a blowing agent into the foamable gel, and passing the gel through a die to form the foam. It can be manufactured by forming an article. Prior to mixing with the blowing agent, the polymeric material is heated to a temperature above its glass transition temperature or melting point. The blowing agent can be prepared by any means known in the art (eg, extruders,
Mixer or blender) can also be introduced or mixed into the molten polymer material. The blowing agent is mixed with the molten polymer material at a high pressure sufficient to prevent substantial expansion of the molten polymer material and at a high pressure sufficient to uniformly disperse the blowing agent. The amount of blowing agent introduced is from about 0.06 to 0.17 gram-mol per 100 g of polymer. A nucleating agent such as talc is blended into the polymer melt or dry blended with the polymer material prior to plasticizing or melting. Generally, the foamable gel is cooled to a lower foaming temperature to optimize the desired physical properties of the foam. The gel may be cooled in an extruder or other mixing device, or may be cooled in a separate cooler. The foaming temperature must be high enough to allow the formation of an open cell structure, but low enough to prevent collapse of the foam when extruded. Desirable foaming temperature is about 1
The range is from 05 ° C to about 160 ° C, preferably from about 120 ° C to about 135 ° C. The gel is then extruded or conveyed through a die of desired shape into a zone of reduced or lower pressure to form a foam. The lower pressure zone is at a pressure lower than the pressure at which the foamable gel is held prior to extrusion through the die. The lower pressure may be overpressure or decompression (evacuation or vacuum), but is preferably at atmospheric pressure.

Open cell polyurethane and polyisocyanurate foams can be made by reacting two pre-blended components, commonly referred to as A and B components. The blowing agent may be dispersed in the isocyanate, in the polyol, or in both.

Suitable polyisocyanates include m-phenylene diisocyanate, toluene-2,4-diisocyanate, toluene-2,6-diisocyanate, a mixture of 2,4-toluene diisocyanate and 2,6-toluene diisocyanate, hexamethylene -1,6-diisocyanate, tetramethylene-1,4-diisocyanate, cyclohexane-1,4-diisocyanate, hexahydrotoluene-2,4-diisocyanate, hexahydrotoluene-2,6-diisocyanate, naphthalene-1,5- Diisocyanate, diphenylmethane-4,4'-diisocyanate, 4,4'-diphenylene diisocyanate, 3,3'-dimethoxy-4
Diisocyanates such as 4,4'-biphenyl diisocyanate, 3,3'-dimethyl-4,4'-biphenyl diisocyanate, and 3,3'-dimethyldiphenylmethane-4,4'-diisocyanate; 4,4 ', 4 "- Triphenylmethane-triisocyanate, polymethylene polyphenylisocyanate, toluene-2,4,6-
Triisocyanates such as triisocyanate; and tetraisocyanates such as 4,4'-dimethyldiphenylmethane-2,2 ', 5,5 "-tetraisocyanate.

Suitable polyols include ethylene glycol; propylene glycol- (
1,2) and-(1,3); butylene glycol- (1,4) and-(2,3)
Hexanediol- (1,6); octanediol- (1,8); neopentyl glycol; 1,4-bishydroxymethylcyclohexane; 2-methyl-1,3
-Propanediol; glycerin; trimethylolpropane; trimethylolethane; hexanetriol- (1,2,6); butanetriol- (1,2,4);
Pentaerythritol; quinitol; mannitol; sorbitol; formitol; α-methylglucoside; diethylene glycol;
Tetraethylene glycol and higher polyethylene glycol; dipropylene glycol and higher polypropylene glycol; and dibutylene glycol and higher polybutylene glycol. Suitable polyols further include diethylene glycol, dipropylene glycol, triethylene glycol, tripropylene glycol, tetraethylene glycol, tetrapropylene glycol,
There are oxyalkylene glycols such as trimethylene glycol and tetramethylene glycol.

The polyurethane foam comprises a polyol and an isocyanate in a ratio of 0.7: 1 to 1.
It can be produced by reacting at an equivalent ratio of 1: 1. The polyisocyanurate foam of the present invention is used in an amount of about 0.1 to 0.1 per equivalent of polyisocyanate.
Advantageously, it is prepared by reacting a polyisocyanate with a lower amount of polyol so that a hydroxyl equivalent of a polyol of 70 is obtained.
Useful polyurethane and polyisocyanurate foams and methods for making them are described in U.S. Patent Nos. 3,580,869; 4,795,763; 5,260,34.
4, No. 5,288,766; 5,334,624; and 5,346,928 (
These patents are incorporated herein by reference).

Aerogels may be composed of various materials (eg, silica, metal oxides, carbon, and formaldehyde derivatives). Aerogels and their method of manufacture are described in U.S. Patent Nos. 5,081,163; 5,242,647; 5,275,796;
Nos. 5,358,802; 5,381,149; and 5,395,805, which are incorporated herein by reference.

The microcellular thermoplastic foam may be somewhat cross-linked or non-cross-linked. "Non-crosslinked" means that the foam is substantially free of crosslinks. However, the term includes the slight degree of crosslinking that occurs naturally without the use of crosslinking agents or radiation. ASTM D
According to Method A of -2756-84, the non-crosslinked foam contains no more than 5% gel.

Useful foams include open-cell propylene polymer foams such as US Pat. Nos. 5,348,795 and 5,567,742, which are hereby incorporated by reference. Form]. Useful propylene polymer foams include extruded foams composed of agglomerated strands, especially those having an open cell content of about 50% or more, preferably about 80% or more, and most preferably about 95% or more. There is a form.

Agglomerated strand extruded foams are particularly useful because they can be evacuated faster than foams extruded from conventional slits or dies (or conventional single structure slits or dies). The cohesive strand extruded foam clearly shows continuous channels between the strands extending in the extrusion direction of the foam. Agglomerated strand foam can be an open channel or a closed channel (open channel) depending on how densely the aggregated strands are packed.
closed channel) form. An open channel form is one in which the majority of the strand-strand interface clearly defines a continuous channel such that it is visible to the naked eye that it is open at the end or cross section. A closed channel form is one in which the majority of the strand-strand interface clearly defines a continuous channel that is visible to the naked eye at end or cross section. Closed channel foams exhibit faster evacuation times than conventional single structure foams. Open channel foams exhibit faster evacuation times than conventional single structure foams and closed channel foams. An evacuated insulation panel comprising a coherent strand foam in an open channel configuration or a closed channel configuration is within the scope of the present invention. Stranded foam structures are described in U.S. Patent Nos. 4,824,720 and 5,124,097, which are incorporated herein by reference. Exhaust or suction is primarily in the direction along the continuous channel (extrusion direction), but may be from any direction (eg, generally perpendicular to the direction of the continuous channel). . Although the use of a coherent strand foam structure is preferred when a continuous channel is required, the conventional or partial perforation using nails, needles, or the like, provides a more conventional method. It is also within the scope of the present invention to introduce multiple or multiple channels in a unitary foam.
Foam piercing is described in U.S. Patent No. 5,585,058, which is hereby incorporated by reference.

The evacuated panel may be (a) place the foam inside a receptacle or enclosure (eg, a bag that can be hermetically sealed or hermetically sealed); (b) inside the receptacle or enclosure. And evacuating the foam to a partial or near full vacuum; (c) sealing the receptacle or enclosure to make it airtight or hermetically sealed. The interior of the evacuated panel or vacuum panel is evacuated to an absolute pressure of about 10 Torr or less, more preferably to about 1 Torr or less, and most preferably to about 0.1 Torr or less. I do. Prior to introducing the foam into the evacuated panel, the foam can be compressed to increase its thermal insulation capacity per unit thickness or unit volume, and / or simultaneously compressed and heated to increase dimensional stability be able to. To increase the thermal insulation capacity per unit thickness, alkenyl aromatic polymer foams and polyurethane /
Polyisocyanate foams can be compressed to about 30 to about 70% of their initial thickness. To enhance dimensional stability, the alkenyl aromatic polymer foam should be 90-95% of the initial thickness (preferably a lower percentage of the initial thickness).
Compression and heating can be performed simultaneously. A description of compression and simultaneous compression and heating is provided in WO 97/27986, filed Jul. 14, 1997, and in Attorney Docket 43401, which are incorporated herein by reference. I have. The skin layer of the foam may further be sliced or flattened to better expose the open cell structure of the foam. The foam may be degassed by any means known in the art (eg,
Evacuation can be achieved by using a suction nozzle or by placing it in an exhaust chamber.

The evacuated panel receptacle or enclosure may be formed of any material known in the art. One embodiment of the evacuated panel is:
Uses a receptacle or enclosure formed of a laminate sheet containing three or more layers. The outer layer comprises a scratch resistant material (eg, polyester). The intermediate layer includes a barrier material (eg, aluminum, polyvinylidene chloride, or polyvinyl alcohol).

To further enhance the long-term performance of the vacuum panel, a “getter” material can be provided inside the evacuated panel. The getter material adsorbs gases and / or vapors that penetrate or permeate the vacuum panel over time. Conventional getter materials include metals such as barium, aluminum, magnesium, calcium, iron, nickel, and vanadium, and alloys of these metals. Suitable getter materials include U.S. Patent Nos. 5,191,980; 5,312,606; 5,312,607; and WO 93/25843, which are hereby incorporated by reference. There are substances listed.

Another type of useful getter material is a conventional desiccant that is useful for absorbing water vapor or moisture. Such materials are advantageously incorporated into the exhaust insulation panel in the form of a porous or permeable wrapper or receptacle having the material contained therein. Useful materials include silica gel, activated alumina, activated carbon, aluminum-rich zeolites, calcium chloride, calcium oxide, and calcium sulfate. A preferred substance is calcium oxide.

As used herein, “automobile” refers to a car, a truck, a light truck, a bus, a tractor, a construction vehicle, and other vehicles that use conventional small auto-type batteries. Includes most recent developments, including motor vehicles such as vehicles, as well as larger electrical arrangements (eg, electric cars and fuel cells). As used herein, "vehicle" includes all types of vehicles, including automobiles, boats, ships, airplanes, rockets, and spacecraft, unless otherwise specified. As used herein, "engine compartment" can be any vehicle engine compartment where the insulated heat sensitive member can be located on, in, or near the vehicle.

[0053] US Provisional Patent Application 60 / 061,963 filed October 14, 1997 and US Provisional Patent Application 60 / 068,032 filed December 18, 1997 are hereby incorporated by reference. include.

The present invention can be applied to insulate any heat sensitive vehicle components. Such a member may be any functional device or apparatus that contributes to the operation or usefulness of the vehicle. EXAMPLES Example 1 An insulated battery of the present invention was manufactured and placed in an engine compartment of a motor vehicle to test the effectiveness of the insulated battery in maintaining temperature control within the battery.

The front (electrode side) and the two sides of the Group 75 automotive battery were tightly covered by evacuated insulation panels. A representative example of an insulated battery is shown in FIG. The evacuated panel contained a propylene polymer extruded foam with an open cell content of 80%. The open cells of the foam were evacuated to an absolute pressure of about 0.1 Torr and the foam was sealed in a gas impermeable laminate bag. Foam and panel thickness was 0.27 inches (0.68 cm). The panel exhibited an R value of 14.4 / inch.

As shown in FIG. 1, the insulated battery was placed at the front of the engine compartment, facing the engine on the passenger side. Pontiac Gr
and Prix) were studied in the R-15-61 driving cycle. In this cycle, the car was subjected to the following sequence: 60 miles /
Drive the test track 3 laps at time (mph); 0 on the rural highway
Driving for 0.4 hours; driving on urban roads for 0.9 hours; idling the car for 0.4 hours; turning off the engine and cooling down for 0.3 hours; grade / towing for 0.8 hours ( (grade / towing) (3.7 laps at 30 mpH); and drive at high speed for 2 laps on the test track for 0.8 hours. The cycle is performed at an average ambient temperature of 95F. The total test time is 4.6 hours.

The temperature performance of the insulated battery is determined by comparing the temperature of the outer surface of the evacuated foam on the front side and the temperature of the outer surface of the battery case adjacent to the evacuated panel on the front side. Measured by comparison. Testing of the insulated battery has shown that the outer surface temperature of the battery case closely corresponds to the temperature of the electrolyte inside the battery.

As shown in FIG. 5, the insulated battery allowed for excellent control of the electrolyte temperature. The two temperatures recorded were not equal until 4 hours had elapsed. In addition, about three hours had passed before the temperature of the electrolyte reached the critical temperature of 60 ° C (140 ° F). Example 2 An insulated battery of the present invention was manufactured and placed in the engine compartment of a diesel truck to test its effectiveness in maintaining temperature control within the battery.
This battery was one of two insulated batteries located in the engine compartment.

[0059] The front panel (electrode surface) and the two side panels of the Group 75 automotive battery were tightly covered by the evacuated insulation panels. A representative example of an insulated battery is shown in FIG. The evacuated panel was the same as in Example 1.

As shown in FIG. 2, the insulated battery was placed in front of the engine compartment on the passenger side. Another insulated battery was placed on the driver side. This diesel truck was studied in the R-15-61 operation cycle described in Example 1.

The temperature behavior of the insulated battery was measured as described in Example 1. As shown in FIG. 6, the insulated battery showed good control of electrolyte temperature. Monitored over 4.5 hours, the two temperatures were quite different. Example 3 The effectiveness of the insulated battery of the present invention located in the engine compartment of a gasoline powered truck in temperature control was tested. This battery was one of two insulated batteries located in the engine compartment.

The front panel (electrode surface) and the two side panels of the Group 75 automotive battery were covered exactly by the evacuated heat insulating panels. A representative example of an insulated battery is shown in FIG. The evacuated panel was the same as in Example 1.

As shown in FIG. 2, the insulated battery was placed in front of the engine compartment on the passenger side. This diesel truck was studied in the R-15-61 operation cycle described in Example 1.

The adiabatic performance of the battery was measured by tracking the temperature of the electrolyte in the battery.

As can be seen from FIG. 7, the insulated battery showed excellent temperature control performance. The temperature of the electrolyte did not exceed 138 ° F (59 ° C).

Although the embodiments of the insulated battery and engine compartment of the present invention have been described in detail, depending on the type of vehicle and the needs of the manufacturer, the novel disclosure of the present invention and the present invention as described herein It goes without saying that changes may be made by various modifications within the scope of the principle.

[Brief description of the drawings]

FIG. 1 is a plan view of an engine compartment containing an insulated battery of the present invention. FIG. 2 is a plan view of an engine compartment containing two insulated batteries of the present invention. FIG. 3 is a perspective view of an embodiment of the insulated battery of the present invention. FIG. 4 is a perspective view of another embodiment of the insulated battery of the present invention. FIG. 5 is a graph showing the relationship between time and temperature behavior for the insulated battery of the present invention in the engine compartment of a motor vehicle. This figure shows the test results obtained using the insulated battery of Example 1. FIG. 6 is a graph showing time versus temperature behavior for the insulated battery of the present invention in the engine compartment of a diesel truck. This figure is
4 shows test results obtained using the insulated battery of Example 2. FIG. 7 is a graph showing time versus temperature behavior for the insulated battery of the present invention in the engine compartment of a gasoline powered truck. This figure shows the test results obtained using the insulated battery of Example 3.

[Procedure amendment]

[Submission date] December 27, 2000 (2000.12.27)

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──────────────────────────────────────────────────続 き Continued on the front page (31) Priority claim number 60 / 087,147 (32) Priority date May 29, 1998 (May 29, 1998) (33) Priority claim country United States (US) ( 81) Designated countries EP (AT, BE, CH, CY, DE, DK, ES, FI, FR, GB, GR, IE, IT, LU, MC, NL, PT, SE), OA (BF, BJ, CF, CG, CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG), AP (GH, GM, KE, LS, MW, SD, SZ, UG, ZW), EA (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM), AL, AM, AT, AU, AZ, BA, BB, BG, BR, BY, CA, CH, CN, CU, CZ, DE, K, EE, ES, FI, GB, GE, GH, GM, HR, HU, ID, IL, IS, JP, KE, KG, KP, KR, KZ, LC, LK, LR, LS, LT, LU, LV, MD, MG, MK, MN, MW, MX, NO, NZ, PL, PT, RO, RU, SD, SE, SG, SI, SK, SL, TJ, TM, TR, TT, UA, UG , US, UZ, VN, YU, ZW (72) Inventor Motter, Greg A. 4840, Michigan, USA, Midland, Sylvan Lane 1401 F-term (reference) 5H031 AA01 CC02 EE03 EE04 KK02

Claims (9)

[Claims] 1. A) a heat-sensitive member; and B) a porous or open cell, evacuated and sealed to an absolute pressure of less than about 10 Torr, and covering more than about 20% of the surface area of said member. A core stock made of one or more hard substance matrices, wherein said core stock is optionally placed in an evacuated cavity of said member; or C) until an absolute pressure of less than about 10 Torr A deformable receptacle surrounding the core stock, evacuated and sealed, made of one or more hard or porous material matrices, and covering about 20% or more of the surface area of the member. Wherein said core stock or evacuated panel has an R value of 10 or more per inch. Bringing engine compartment. 2. The core stock, made of one or more porous or open-cell hard material matrices, includes one or more depressions extending in at least one dimension across the surface of the hard material matrix. The outer surface of the evacuated cavity of the receptacle or member has a shape substantially conforming to the shape of the core stock and the depression therein, and the final panel has a substantially unwrinkled surface. The engine compartment of claim 1, further comprising, optionally, one or more rigid plates having one or more recesses and disposed adjacent a major surface of the core stock. 3. The hard material matrix of the core stock is an open cell thermoplastic foam, polycarbonate foam, thermosetting foam, polyurethane foam, epoxy resin foam, formaldehyde foam, phenolic resin foam, isocyanurate foam, silica, glass. The engine compartment according to any one of claims 1 to 2, which is a fiber, a glass bead, an airgel, or a xerogel. 4. The alkenyl aromatic polymer foam, wherein the rigid material matrix of the core stock has an average cell size of less than about 70 micrometers.
The engine compartment according to any one of claims 1 to 2, wherein the engine compartment is a propylene polymer foam, an extruded foam composed of cohesive strands, an open channel foam, or a perforated foam. 5. The engine compartment according to claim 1, wherein the member is a battery, a computer, or a communication device. 6. The engine compartment according to claim 1, wherein said core stock or evacuated panel provides an R value of about 15 or more per inch. 7. The engine compartment of claim 1, wherein the absolute pressure in the core stock is less than about 1.0 Torr. 8. The engine compartment according to claim 1, wherein the member is a lead-acid battery and the engine compartment is an engine compartment of an automobile. 9. A) heat-sensitive member; and B) a porous or open cell evacuated and sealed to an absolute pressure of less than about 10 torr and covering more than about 20% of the surface area of said member. A core stock made of one or more hard substance matrices, wherein said core stock is optionally placed in an evacuated cavity of said member; or C) until an absolute pressure of less than about 10 Torr A deformable receptacle surrounding the core stock, evacuated and sealed, made of one or more hard or porous material matrices, and covering about 20% or more of the surface area of the member. Wherein said core stock or evacuated panel has an R value of 10 or more per inch. The resulting thermally insulated heat sensitive element.