JP2022506006A - 防火物品及び関連する方法 - Google Patents
防火物品及び関連する方法 Download PDFInfo
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- JP2022506006A JP2022506006A JP2021512632A JP2021512632A JP2022506006A JP 2022506006 A JP2022506006 A JP 2022506006A JP 2021512632 A JP2021512632 A JP 2021512632A JP 2021512632 A JP2021512632 A JP 2021512632A JP 2022506006 A JP2022506006 A JP 2022506006A
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Abstract
Description
外側主表面上に配置された受動的断熱材であって、複数の非溶解性繊維を含む、受動的断熱材と、を備え、防火物品は、1100℃破壊強度試験において少なくとも10秒の破壊時間を示す。
本明細書で使用される場合、
「周囲条件」は、25℃かつ101.3kPaの圧力を意味する。
一実施形態による防火物品を図1に示し、以降では参照数字100で示す。防火物品100は、火源の方に向けられている。明確にするために、図1のブロック矢印は、火災伝播が入って来る予想される方向を示す。防火物品の向きに関するこの取り決めは、図2~図4にも適用されるものとする。
提供される防火物品は防火バリアを組み込んでおり、防火バリアは、火災の伝播を防止又は遅延させるだけでなく、電池火災が開始したときに電池セルの排気によって生成されるガスの膨張から生じ得る圧力衝撃に耐え抜くように、防火物品に強度を提供する。排気されたガスは約150℃の温度を有する場合があり、この温度が、防火バリア材料の引張特性を評価するための有意性のある参照温度になる。防火バリアは、好ましくは、不燃性繊維の織布又は不織布ウェブなど可撓性かつ不燃性の材料から作製される。
受動的断熱材は、複数の非溶解性繊維を含有する。好ましい実施形態では、非溶解性繊維は、不織繊維ウェブに加工される。非溶解性繊維は、どんな温度でも液体にならないポリマー又は他の材料から作製される繊維である。場合によっては、これらのポリマーは、空気の存在下で加熱されると、最初に酸化するか又は別の方法で劣化するので、溶解しない。非溶解性ポリマー繊維は、炭素繊維、炭素繊維前駆体、又はこれらの組み合わせを含むことができる。
受動的断熱材は、防火バリアと受動的断熱材とを互いに接合させるために、又は防火バリア若しくは受動的断熱材のいずれかを他の隣接する層若しくは基材に接合させるために、1つ以上のポリマーバインダーを含むことができる。バインダーは、微粒子で若しくは乳化形態で、又は連続フィルムとして下塗り(rendered)されてもよい。場合によっては、繊維脱落の問題を緩和させるために、バインダーは、防火物品の、又はその構成層のいずれかの周縁部を縁部シールすることを可能にすることができる。バインダーは、防火バリア、受動的断熱材、スクリム、及び/又は存在する任意の他の層若しくは基材の一方又は両方の主表面上に配置することができ、次いで、バインダーを溶解させるか、又は別の方法で活性化して、対向する層の表面を互いに接合させることができる。
図面で参照されるスクリムは特に限定されておらず、織布又は不織布である任意の種類の中実フィルム若しくは多孔質フィルム、又はオープンメッシュ構造を含むことができる。スクリムは、防火バリアとは反対側の受動的断熱材の主表面にわたって延びることができ、代替として、受動的断熱材とは反対側の防火バリアの主表面にわたって延びることができる。
更なる変形例が可能である。例えば、受動的断熱材及び/又はスクリム内の繊維を、バインダーではない他の組成物でコーティング又はサイジングすることができる。繊維サイジングは、例えば、シリコーン、アクリレート、及びフルオロポリマーから選択することができ、それにより、受動的断熱材は0.5未満の放射率を有する。ここで、「放射率」は、同じ温度及び波長で、かつ、同じ観察条件下において、材料の表面から放射されるエネルギーと黒体(完全放射体)から放射されるエネルギーの比率として定義される。放射率の低減は、熱放射による材料が熱を損失する程度を低下させるのに役立つ。
不織布ウェブの厚さ測定:嵩高の不織布の厚さについての試験方法に従って、ASTM D5736-95の方法を行った。プレート圧力を0.002psi(13.790パスカル)に較正した。
30cm×30cmの切断領域の100%(重量で)のOPAN 1を、この繊維をSantex AG製のWave-Makerシステムに通過させてカーディングし、150gsmのコアウェブを形成した。次いで、このコアウェブを、75ニードル/列の23列のニードルボードアレイを有するDilo Needle Loom,Model DI-Loom OD-1 6(Eberbach,Germany)に搬送した。これらの列は、パターンをランダム化するためにわずかにオフセットされている。ニードルは、Foster 20 3-22-1.5Bのニードルであった。アレイは、機械方向の深さがおよそ17.8cm、名目上の幅が61cmであり、ニードル間隔はおよそ0.76cmであった。ウェブを絡み合わせ圧縮するために、ニードルボードを91ストローク/分で動作させた。ウェブ厚は10mmであった。
2018年5月24日に公開された同一所有者のPCT国際出願第2018/093624号のSol Making Method 2及びFiber Spinning Method 1に記載のプロセス及び技術によって、実質的に連続した繊維から作製された繊維状多結晶酸化物不織マット(PolyX不織マット1)を組み立て、ニードル加工した。より具体的には、Groz-beckert USA(Fort Mill,South Carolina)製のニードルタイプ15×18×32×3 1/2 U333を装填したFeltloom(Sharpsburg,Kentucky)製のニードルタッカーを使用して、緑色繊維ウェブを機械的に絡み合わせた。各試料をニードルタッカーに1回通過させた後、試料をひっくり返してから再び装置に通過させた。最終的なパンチング密度を計算すると約25パンチ/cm2であった。次に、ニードル処理した緑色繊維ウェブを焼成し、1285℃~1300℃の焼結温度で焼結してセラミックマットにした。
2018年5月24日に公開された同一所有者のPCT国際出願第2018/093624号のSol Making Method 2及びFiber Spinning Method 1に記載のプロセス及び技術によって、実質的に連続した繊維から作製された繊維状多結晶酸化物不織マット(PolyX不織マット2)を組み立てた。しかしながら、マットを束縛させるためにニードリング技術を使用するのではなく、繊維が多孔質コレクタ上に堆積されるにつれて、シリコーン潤滑剤湿潤無機バインダーをマット上にコーティングした。次いで、繊維を焼成し、1285℃~1300℃の焼結温度で焼結してセラミックマットにした。
厚さ0.8cmのOPANマット試料に、小規模バーンスルー試験を行った。結果を表2に示す。
厚さ0.5cmのHi-Loftバーンスルー絶縁材試料に、小規模バーンスルー試験を行った。結果を表2に示す。
準備的実施例2の厚さ0.5cmのPolyX不織マット1試料に、小規模バーンスルー試験を行った。結果を表2に示す。
準備的実施例3の厚さ0.27cmのPolyX不織マット2試料に、小規模バーンスルー試験を行った。結果を表2に示す。
準備的実施例1で組み立てたOPAN1コアウェブの30cm×30cmの試料を、手作業で30cm×30cmのFR PETスクリム上に接着剤で積み重ね、準備的実施例2の30cm×30cmのPolyX不織マット1を、OPAN1コアウェブ上に手作業で積み重ねた。厚さ1.65cm、900gsmの積層試料を所定寸法に切断し小規模バーンスルー試験を行った。結果を表2に示す。
準備的実施例1で組み立てたOPAN1コアウェブの30cm×30cmの試料を、手作業で30cm×30cmのFR PETスクリム上に接着剤で積み重ね、準備的実施例3の30cm×30cmのPolyX不織マット2を、準備的実施例1で組み立てたOPAN1コアウェブ上に手作業で積み重ねた。厚さ1.4cm、529gsmの積層試料を所定寸法に切断し小規模バーンスルー試験を行った。結果を表2に示す。
厚さ0.8cmのOPANマット試料に、1100℃破壊強度試験を行った。結果を表3に示す。
厚さ0.5cmのHi-Loftバーンスルー絶縁材試料に、1100℃破壊強度試験を行った。結果を表3に示す。
準備的実施例2の厚さ0.5cmのPolyX不織マット1試料に、1100℃破壊強度試験を行った。結果を表3に示す。
準備的実施例3の厚さ0.27cmのPolyX不織マット2試料に、1100℃破壊強度試験を行った。結果を表3に示す。
準備的実施例1で組み立てたOPAN1コアウェブの30cm×30cmの試料を、手作業で30cm×30cmのFR PETスクリム上に接着剤で積み重ね、準備的実施例2の30cm×30cmのPolyX不織マット1を、OPAN1コアウェブ上に手作業で積み重ねた。厚さ1.65cm、900gsmの積層試料を所定寸法に切断し、1100℃破壊強度試験を行った。結果を表3に示す。
準備的実施例1で組み立てたOPAN1コアウェブの30cm×30cmの試料を、手作業で30cm×30cmのFR PETスクリム上に接着剤で積み重ね、準備的実施例3の30cm×30cmのPolyX不織マット2を、準備的実施例1で組み立てたOPAN1コアウェブ上に手作業で積み重ねた。厚さ1.4cm、529gsmの積層試料を所定寸法に切断し、1100℃破壊強度試験を行った。結果を表3に示す。
厚さ0.8cmのOPANマット試料に、引張強度試験を行った。結果を表4に示す。
厚さ0.5cmのHi-Loftバーンスルー絶縁材試料に、引張強度試験を行った。結果を表4に示す。
準備的実施例2の厚さ0.5cmのPolyX不織マット1試料に、引張強度試験を行った。結果を表4に示す。
準備的実施例3の厚さ0.27cmのPolyX不織マット2試料に、引張強度試験を行った。結果を表4に示す。
準備的実施例1で組み立てたOPAN1コアウェブの30cm×30cmの試料を、手作業で30cm×30cmのFR PETスクリム上に接着剤で積み重ね、準備的実施例2の30cm×30cmのPolyX不織マット1を、OPAN1コアウェブ上に手作業で積み重ねた。厚さ1.65cm、900gsmの積層試料を所定寸法に切断し、引張強度試験を行った。結果を表4に示す。
準備的実施例1で組み立てたOPAN1コアウェブの30cm×30cmの試料を、手作業で30cm×30cmのFR PETスクリム上に接着剤で積み重ね、準備的実施例3の30cm×30cmのPolyX不織マット2を、準備的実施例1で組み立てたOPAN1コアウェブ上に手作業で積み重ねた。厚さ1.4cm、529gsmの積層試料を所定寸法に切断し、引張強度試験を行った。結果を表4に示す。
Claims (15)
- 複数の不燃性繊維を含む防火バリアと、
前記防火バリアに結合された受動的断熱材であって、複数の非溶解性繊維を含む、受動的断熱材と、を備える防火物品であって、1100℃破壊強度試験において少なくとも10秒の破壊時間を示す、防火物品。 - 複数の不燃性繊維を含む防火バリアと、
前記防火バリアに結合された受動的断熱材であって、複数の非溶解性繊維を含む、受動的断熱材と、を備える防火物品であって、150℃において少なくとも5kPaの最小引張強度を示す、防火物品。 - 複数の不燃性繊維を含む防火バリアと、
前記防火バリアに結合された受動的断熱材であって、複数の非溶解性繊維を含む、受動的断熱材と、を備える防火物品であって、前記防火バリアは、相互に絡み合った実質的に連続した繊維を含む、防火物品。 - 前記不燃性繊維は、700℃~2000℃の範囲内の溶解温度を有する、請求項1~3のいずれか一項に記載の防火物品。
- 前記不燃性繊維はアルミナシリケートを含む、請求項1~4のいずれか一項に記載の防火物品。
- 前記非溶解性繊維は酸化ポリアクリロニトリルを含む、請求項1~5のいずれか一項に記載の防火物品。
- 前記防火バリアと前記受動的断熱材とを互いに結合するポリマーバインダーを更に含む、請求項1~6のいずれか一項に記載の防火物品。
- 前記ポリマーバインダーは、フルオロポリマーバインダーを含む、請求項7に記載の防火物品。
- 前記防火バリアとは反対側の前記受動的断熱材の主表面にわたって延びるスクリムを更に備える、請求項1~8のいずれか一項に記載の防火物品。
- 前記受動的断熱材とは反対側の前記防火バリアの主表面にわたって延びるスクリムを更に備える、請求項1~9のいずれか一項に記載の防火物品。
- 前記スクリムはポリエステルを含む、請求項9又は10に記載の防火物品。
- 前記スクリム又は前記受動的断熱材は周縁部を有し、前記スクリム及び前記受動的断熱材は前記周縁部に沿って縁部シールされている、請求項10又は11に記載の防火物品。
- 電気自動車用の電池コンパートメントであって、
内側主表面及び外側主表面を有するコンパートメント壁であって、前記内側主表面がエンクロージャの少なくとも一部を提供する、コンパートメント壁と、
前記内側表面上又は外側表面上のいずれかに配置された請求項1~12のいずれか一項に記載の防火物品と、を備える、電池コンパートメント。 - 電気自動車用の電池コンパートメントであって、
内側主表面及び外側主表面を有する少なくとも1つのコンパートメント壁であって、前記内側主表面がエンクロージャの少なくとも一部を画定する、少なくとも1つのコンパートメント壁と、
前記内側主表面上に配置された防火バリアであって、複数の不燃性繊維を含む、防火バリアと、
前記外側主表面上に配置された受動的断熱材であって、複数の非溶解性繊維を含む、受動的断熱材と、を備え、
前記防火物品は、1100℃破壊強度試験において少なくとも10秒の破壊時間を示す、電池コンパートメント。 - 防火物品の製造方法であって、
複数の不燃性繊維を含む防火バリアの外側表面上にポリマーバインダーをコーティングすることと、
前記コーティングされた前記防火バリアを、複数の非溶解性繊維を含む受動的断熱材と接触させて配置することと、
前記ポリマーバインダーを加熱して、前記防火バリアと前記受動的断熱材とを互いにラミネートして、前記防火物品に、1100℃破壊強度試験において少なくとも10秒の破壊時間を提供することと、を含む、方法。
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WO2023190539A1 (ja) * | 2022-03-29 | 2023-10-05 | 凸版印刷株式会社 | 電池パック |
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CN112714976A (zh) | 2021-04-27 |
EP3847715A4 (en) | 2022-04-13 |
WO2020047846A1 (en) | 2020-03-12 |
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