Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
  • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
  • H01B3/02—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances
  • H01B3/08—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances quartz; glass; glass wool; slag wool; vitreous enamels
  • H01B3/084—Glass or glass wool in binder
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
  • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
  • H01B3/002—Inhomogeneous material in general
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B60—VEHICLES IN GENERAL
  • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
  • B60L50/00—Electric propulsion with power supplied within the vehicle
  • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
  • B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
  • B60L50/64—Constructional details of batteries specially adapted for electric vehicles
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K21/00—Fireproofing materials
  • C09K21/02—Inorganic materials
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/413—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties containing granules other than absorbent substances
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4209—Inorganic fibres
  • D04H1/4218—Glass fibres
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
  • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
  • H01B3/02—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances
  • H01B3/025—Other inorganic material
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
  • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
  • H01B3/02—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances
  • H01B3/04—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances mica
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/60—Heating or cooling; Temperature control
  • H01M10/62—Heating or cooling; Temperature control specially adapted for specific applications
  • H01M10/625—Vehicles
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/60—Heating or cooling; Temperature control
  • H01M10/65—Means for temperature control structurally associated with the cells
  • H01M10/653—Means for temperature control structurally associated with the cells characterised by electrically insulating or thermally conductive materials
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
  • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
  • H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
  • H01M50/24—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries from their environment, e.g. from corrosion
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/60—Heating or cooling; Temperature control
  • H01M10/65—Means for temperature control structurally associated with the cells
  • H01M10/655—Solid structures for heat exchange or heat conduction
  • H01M10/6554—Rods or plates
  • H01M10/6555—Rods or plates arranged between the cells
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M2220/00—Batteries for particular applications
  • H01M2220/20—Batteries in motive systems, e.g. vehicle, ship, plane
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/10—Energy storage using batteries
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T10/00—Road transport of goods or passengers
  • Y02T10/60—Other road transportation technologies with climate change mitigation effect
  • Y02T10/70—Energy storage systems for electromobility, e.g. batteries

Definitions

• the present invention is directed to a flame resistant electrical insulating material for use in electric vehicles.
• the exemplary electrical insulating material can be formed as flame resistant inorganic paper(s) or board(s) capable of passing UL 94-VO, 5VA flame resistance tests.
• some exemplary flame resistant inorganic paper or board materials can withstand direct exposure to a 2054°C (3730°F) flame for at least 10 minutes without puncturing. Such inorganic paper or boards are thus useful as a protective device, such as a thermal or flame barrier for electric vehicle battery applications.
• mica boards e g., boards including at least 80% mica
• the high density of mica boards can make mica boards a less attractive solution for electric vehicle battery applications desiring lighter weight materials. Additionally, the ability to adhere mica boards to a substrate or other product parts may limit their use in certain applications.
• Inorganic ceramic papers are made from refractory ceramic fibers and can provide excellent high temperature (> 1000C) thermal insulation and flame resistance properties.
• refractory ceramic fibers are classified as being possibly carcinogenic to humans (Group 2B) by the International Agency for Research on Cancer (IARC). While low
• biopersistent refractory ceramic fibers have been developed to address the health concerns, they are more expensive.
• the space allowed for flame barrier materials in many electric vehicles can be quite limited (e.g., less than 3 mm) which restricts the use of many thicker flame barrier and thermally insulating materials. Additionally, due to the wide range of battery modules and pack designs, as well as, the different battery cell types with varying levels of energy density, flame resistant materials are needed at varying levels of performance. The trend in the electric vehicle industry is towards the use of higher energy density battery cells as a means to increased driving range.
• Exemplary electrical insulating materials in the form of flame resistant, inorganic paper(s) or board(s) of the present invention are able to withstand harsh, high temperature flammability tests while also providing low thermal conductivity for thermal insulation and low density for reduced weight. Formulations can be tailored to meet differing customer
• a flame resistant electrical insulating material comprises glass fibers, a particulate filler mixture, and an inorganic binder, wherein the electrical insulating material has a UL-94 flammability rating of V-0, 5VA and a thermal conductivity of less than 0.15 W/m-K.
• the particulate filler mixture comprises at least two particulate filler materials selected from the list of glass bubbles, kaolin clay, talc, mica, calcium carbonate, and alumina trihydrate.
• a flexible flame resistant electrical insulating material comprises glass fibers, a particulate filler mixture, and an inorganic binder, wherein the electrical insulating material has a UL-94 flammability rating of V-0, 5VA, and wherein the flexible material is capable of wrapping around a mandrel without cracking or damaging the material.
• the particulate filler mixture comprises at least two particulate filler materials selected from the list of glass bubbles, kaolin clay, talc, mica, calcium carbonate, and alumina trihydrate.
• a flame resistant electrical insulating material comprises glass fibers, a particulate filler mixture, and an inorganic binder, wherein the electrical insulating material has a UL-94 flammability rating of V-0, 5VA.
• the particulate filler mixture comprises at least two particulate filler materials selected from the list of glass bubbles, kaolin clay, talc, mica, calcium carbonate, and alumina trihydrate.
• a flame resistant electrical insulating material comprises 3 wt.% to 25 wt.% glass fibers; 20 wt.% to 80 wt.% of kaolin clay; 5 wt.% to 15 wt.% glass bubbles; and 5 wt.% to 20 wt.% inorganic binder, based on the composition of the insulating material and wherein the insulating material has a UL-94 flammability rating of V-0, 5VA.
• the exemplary flame resistant inorganic paper or board materials can withstand direct exposure to a 2054°C (3730°F) flame for at least 10 minutes without puncturing.
• Fig. 1 shows an exemplary battery module that includes a thermal barrier formed from an insulation material according to an aspect of the invention.
• Fig. 2 shows an exemplary battery pack that includes a thermal barrier formed from an insulation material according to an aspect of the invention.
• Suitable flame resistant electrical insulating materials include inorganic fibers, such as glass fibers, and are thermally and electrically insulating in the form of an inorganic insulating paper or board. Multiple sheets, i.e., plies or sub-layers of inorganic paper layer may be wet laminated and pressed to yield an inorganic board or a multilayer paper material that is thermally and electrically insulating.
• the term“paper” refers to a flexible single or multilayer material that has sufficient flexibility to be bent around a 3-in. mandrel.
• the term“board” refers to a relatively stiff material that can be flexed, but which is not capable to wrap around a mandrel. Electrical insulating materials of the invention containing one or both of inorganic fibers and inorganic particles may be referred to as inorganic papers or boards depending on thickness and flexibility of the insulating material.
• the nonwoven, inorganic papers and boards of the present invention are largely made up of inorganic materials (i.e. inorganic fibers and fillers).
• the exemplary nonwoven, inorganic papers and boards comprise at least 95% inorganic materials.
• the exemplary nonwoven, inorganic papers and boards comprise at least 98% inorganic materials.
• the highly inorganic nature of the exemplary nonwoven, inorganic papers and boards enhances the flame resistance of these materials over most conventional insulating papers.
• Exemplary flame-resistant nonwoven, inorganic papers or boards are able to pass E1L 94- V0, 5VA flame resistance tests and withstand direct exposure to a 2054°C (3730°F) flame for at least 10 minutes without puncture or breaking.
• the exemplary flame-resistant materials, described herein, are also lower density than mica boards, leading to a lower weight insulation solution which is important to electric vehicle manufacturers.
• the exemplary flame-resistant materials also have a lower thermal conductivity than mica boards which reduces the rate of heat transfer to minimize or reduce the propagation of a thermal runaway event to neighboring flammable components, which can reduce the overall severity of the event.
• the exemplary inorganic paper comprises a combination of glass fibers and microglass fibers. These fibers interlock together to form the structural support of the inorganic fillers.
• the glass fiber content of the paper will be from about 3 wt.% to 25 wt.%, with the ratio of glass staple fibers to micro glass fibers being 5: 1 to 1 :3.
• the diameter of the glass fibers can affect the processing of the paper, as well as the final performance of the resulting inorganic papers or boards.
• Exemplary glass staple fibers diameters are 12 microns or less, although small amounts of larger diameter fibers may be incorporated. Smaller diameter glass fibers have a greater surface area than an equivalent amount of larger diameter fibers enabling entrapment of an increase amount of particulate filler materials.
• the microglass fibers used in the present invention typically have a diameter of less than 5 microns.
• the working diameter range for the glass fibers and glass microfibers is from about 0.1 micron to about 12 microns.
• the length of the glass fibers is selected to obtain a uniform dispersion of the glass fibers in the slurry used to make the exemplary papers. It is noted that if the glass fibers are too short there may not be sufficient interlocking between the fibers, and the strength of the resulting paper and boards may be diminished. If the glass fibers are too long, it can be difficult to obtain the uniform dispersion needed.
• the glass fibers should have an average length less than 0.5 inch (12,700 microns) and more preferably about 0.25 inch (6350 microns) and greater than 0.125 inch (3175 microns).
• the glass fibers may also be further identified by a length-to-diameter (L/D) ratio.
• L/D ratio for the glass staple fibers used in the exemplary papers and boards are between 3000: 1 and 200: 1, preferably about 1000: 1.
• the nonwoven paper also comprises one or more inorganic particulate fillers.
• Exemplary inorganic particulate fillers are generally non-endothermic. Suitable inorganic particulate fillers include, but are not limited to, glass bubbles, kaolin clay, talc, mica, calcium carbonate, wollastonite, montmorillonite, smectite, bentonite, illite, chlorite, sepiolite, attapulgite, halloysite, vermiculite, laponite, rectorite, perlite, and combinations thereof, preferably a particulate filler mixture comprises at least two of glass bubbles, kaolin clay, talc, mica, calcium carbonate, and alumina trihydrate.
• kaolin clay examples include, but are not limited to, water-washed kaolin clay; delaminated kaolin clay; calcined kaolin clay; and surface-treated kaolin clay.
• inorganic particulate filler comprises glass bubbles, kaolin clay, mica and mixtures thereof.
• an endothermic filler such as alumina trihydrate, can be added.
• the particulate inorganic filler content of the paper will be from about 65 wt.% to 87 wt.%.
• the exemplary papers of the present invention comprise a mixture of particulate inorganic fillers.
• the exemplary papers and boards comprise between about 20 wt.% to 45 wt.% of kaolin clay, from about 25 wt.% to 45 wt.% mica, and from about 5 wt.% to 15 wt.% glass bubbles based on the total weight of the exemplary paper.
• the exemplary papers and boards comprise between about 55 wt.% to 80 wt.% of kaolin clay and from about 5 wt.% to 15 wt.% glass bubbles based on the total weight of the exemplary paper.
• the exemplary inorganic paper further comprises 5 wt.% - 20 wt.%, preferably 5 wt.% - 15 wt.% inorganic binder.
• the inorganic binder can be selected from sodium silicate, lithium silicate, potassium silicate or a combination thereof.
• processing aids such as defoamers, surfactants, forming aids, pH-adjusting materials, paper strengthening agents, and etc. known to those skilled in the art can also be incorporated.
• the above electrical insulating materials can be used in a protective device or system, such as a thermal/flame barrier.
• a protective device or system such as a thermal/flame barrier.
• one or more sheets of an exemplary electrical insulating material can be incorporated into or wrapped around a flammable energy storage device, such as lithium ion battery cells, modules, or packs, such as may be found in hybrid or electric vehicles or other electric transportation applications or locations.
• Fig. 1 shows an implementation of the exemplary insulation materials described herein.
• a battery module 100 includes an assembly of battery cells 102.
• One or more thermal barrier/flame resistant sheets or boards 110, formed from the exemplary materials described herein, can be disposed between individual battery cells or groups of cells at one or more locations throughout the battery module.
• Fig. 2 shows a lithium ion battery pack 200 that includes a plurality of lithium ion battery modules 202.
• a series of thermal barrier/flame resistant encasement liners 210 are provided to encase one or more of the lithium ion battery modules 202.
• each of the lithium ion battery modules are encased by a thermal barrier/flame resistant encasement liner 210.
• one or more sides of the lithium ion battery pack 200 itself can be wrapped or lined with a thermal barrier/flame resistant encasement liner.
• the exemplary insulation materials described herein can be combined with other functional layers.
• the exemplary insulation materials can be laminated to an inorganic fabric capable of withstanding not only high temperatures, but high pressures as well, to withstand gas venting and particle blow with minimal damage.
• the multilayer material according to the invention may comprise an inorganic fabric which comprises E-glass fibers, R-glass fibers, ECR-glass fibers, basalt fibers, ceramic fibers, silicate fibers, steel filaments or a combination thereof.
• the fibers may be chemically treated.
• the inorganic fabric can be a woven fabric, a knitted fabric, a stitch bonded fabric, a crocheted fabric, an interlaced fabric or a combination thereof.
• the inorganic fabric is a woven basalt fabric.
• the exemplary electrical insulating materials described herein utilize can utilize relatively low temperature glass fibers that are typically used at temperatures below 600°C in combination with filler particles and inorganic binder to achieve high temperature (2000°C) torch flame resistance
• the density of the exemplary paper or board materials is calculated by dividing the basis weight by the thickness.
• the flexibility of the exemplary paper or board materials was determined by bending the materials around a 3-inch mandrel of known diameter without cracking or damaging the material.
• the torch flame test was conducted using a Bernzomatic torch TS-4000 trigger equipped with a MAP Pro fuel cylinder that provides a flame temperature in air of 2054°C/3730°F. Test samples were mounted at a fixed distance of 1” (2.54 cm) from the flame with a metal clip attached at the bottom of the sample to help stabilize the sample against the pressure of the flame and exposed to the flame for a continuous time period of 10 minutes or until the sample was punctured from the flame.
• a sandblast cabinet (Empire Abrasive Equipment Company, Langhome, PA) was used to provide an assessment of resistance to a blast of particles.
• the sample test material was mounted on top of a 3” (76 mm) x 6” (152 mm) metal plate. This sample assembly was then mounted into a fixture within the cabinet and held in place with clamps.
• the sandblast nozzle was fixed at a distance approximately 6” (152 mm) from the sample and tests were conducted at room temperature.
• Steel grit GH40 was used as the blast media and actual compressed air pressure was about 30 psi. A time exposure of 15 seconds was used.
• B-06-F microglass fibers (0.65 pm diameter, 2.47 m 2 /g surface area), available from Lauscha Fiber lnternational Corporation (Charlotte, NC).
• B-26-R microglass fibers (2.44 pm diameter, 0.66 m 2 /g surface area), available from Lauscha Fiber International Corporation (Charlotte, NC).
• N-sodium silicate available from PQ Corporation (Valley Forge, PA).
• TW-600-13-100 basalt twill weave fabric (600 gsm basis weight) available from
• B-06-F microglass fibers (0.65 pm diameter, 2.47 m 2 /g), 28.6 wt.% 200-HK phlogopite mica, 24.5 wt.% calcined kaolin clay Kamin 70C, 9.2 wt.% S15 glass bubbles, 5.1 wt.% phlogopite 20S mica, were pre-dispersed in water to form an aqueous slurry with a solids content of about 0.05-1% by weight in a Waring blender and then mixed into a larger container with 15.2 wt.% delaminated kaolin clay Hydraprint and 10.2 wt.% N-sodium silicate.
• Dewatering was done through a papermaking screen and press (Williams Standard Pulp Testing Apparatus) to form a flame resistant paper material.
• Dewatering was done through a papermaking screen and press (Williams Standard Pulp Testing Apparatus).
• Dewatering was done through a papermaking screen and press (Williams Standard Pulp Testing Apparatus).
• Example 5-P Paper
• Example 6-B (Board)
• Hydraprint clay were pre-dispersed in water at about a 10 wt.% solids content in a Hydrabeater and then transferred to a beater chest that contained a dispersion of 6.9 wt.% EC6-6 E-glass fibers (6 mm length, 6 pm diameter) and 10 wt.% sodium silicate at about a 0.5 wt.% solids. Additional water was added during the final mixing so that the final aqueous slurry solids content was about 1.4 wt.%. The aqueous slurry was then transferred to a millboard machine to make boards in a continuous batch process. After board materials were made, they were dried in an oven for about 8 hours at 300°F. Test results are shown in Table 2.
• Example 8-B (Board)
• aqueous slurry solids content was about 1.4 wt.%.
• the aqueous slurry was then transferred to a millboard machine to make boards in a continuous batch process. After board materials were made, they were dried in an oven for about 8 hours at 300°F. Test results are shown in Table 3.
• Example 8-B was coated with a bead of K® sodium silicate using a syringe. A #30 Mayer rod was then used to draw down and coat the entire sample area. The TW-600-13-100 fabric was placed over the Example 8-B sample and rolled with a 10 lb roller to laminate the fabric layer to the surface of the Example 8-B board. This laminate was then dried at l80°F (82°C) for 5 minutes. Test results are shown in Table 3.
• Example 9-L was coated with a bead of K® sodium silicate using a syringe. A #30 Mayer rod was then used to draw down and coat the entire sample area. The TW-600-13-100 fabric was placed over the Example 9-L sample and rolled with a 10 lb roller to laminate the fabric layer to the surface of the Example 9-L laminate. This laminate was then dried at l80°F (82°C) for 5 minutes. Test results are shown in Table 3.
• Comparative examples 4 and 5 contain no glass bubbles and failed the torch test with burn thru holes after 5 and 2 minutes, respectively. While glass bubbles are typically used for density reduction and thermal insulation purposes, the contribution to preventing a bum thru hole from a high temperature torch for these inventive materials is unexpected.
• Comparative Sample 6 is a 125 mil thick piece of Techmat ® 4008 High Temperature Glass Fiber Insulation - needled 100% E-glass nonwoven mat available from BGF Industries, Inc (Greensboro, NC).
• Comparative Sample 7 is a 17 mil thick piece of Formex ® GK-l7flame retardant polypropylene sheet available from ITW Formex (Carol Stream, IL) ).
• Comparative Sample 8 is a 10 mil thick piece of Nomex ® 410 m-aramid paper available from DuPont (Wilmington, DE).
• Comparative Sample 9 is a 30 mil thick piece of Nomex ® 410 m-aramid paper available from DuPont (Wilmington, DE).
• Comparative Sample 10 is a 9 mil thick piece Flame Barrier FRB-NC229 available from 3M Company (St. Paul, MN). Table 1. Comparison of Properties for Flame Resistant Materials

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Inorganic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Electrochemistry (AREA)
• General Chemical & Material Sciences (AREA)
• Manufacturing & Machinery (AREA)
• Textile Engineering (AREA)
• Materials Engineering (AREA)
• Organic Chemistry (AREA)
• Ceramic Engineering (AREA)
• Transportation (AREA)
• Mechanical Engineering (AREA)
• Power Engineering (AREA)
• Sustainable Energy (AREA)
• Sustainable Development (AREA)
• Life Sciences & Earth Sciences (AREA)
• Paper (AREA)
• Structural Engineering (AREA)
• Laminated Bodies (AREA)
• Civil Engineering (AREA)
• Dispersion Chemistry (AREA)
• Inorganic Insulating Materials (AREA)
• Battery Mounting, Suspending (AREA)

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• 2019
  • 2019-07-22 JP JP2021504219A patent/JP2021531631A/ja not_active Withdrawn
  • 2019-07-22 WO PCT/US2019/042776 patent/WO2020023357A1/en not_active Ceased
  • 2019-07-22 EP EP19753217.9A patent/EP3827447A1/en not_active Withdrawn
  • 2019-07-22 CN CN201980048029.8A patent/CN112424878B/zh not_active Expired - Fee Related
  • 2019-07-22 US US17/250,379 patent/US20210280336A1/en not_active Abandoned

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