WO2023122936A1 - Assemblage de module de batterie - Google Patents

Assemblage de module de batterie Download PDF

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Publication number
WO2023122936A1
WO2023122936A1 PCT/CN2021/141954 CN2021141954W WO2023122936A1 WO 2023122936 A1 WO2023122936 A1 WO 2023122936A1 CN 2021141954 W CN2021141954 W CN 2021141954W WO 2023122936 A1 WO2023122936 A1 WO 2023122936A1
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WO
WIPO (PCT)
Prior art keywords
silicone foam
battery module
battery cells
composition
iii
Prior art date
Application number
PCT/CN2021/141954
Other languages
English (en)
Inventor
Lu Zou
Xiangyang Tai
Xuesi YAO
Yi Guo
Kainan ZHANG
Original Assignee
Dow Silicones Corporation
Dow Global Technologies Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dow Silicones Corporation, Dow Global Technologies Llc filed Critical Dow Silicones Corporation
Priority to PCT/CN2021/141954 priority Critical patent/WO2023122936A1/fr
Publication of WO2023122936A1 publication Critical patent/WO2023122936A1/fr

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    • 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
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
    • 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
    • H01M10/61—Types of temperature control
    • H01M10/613—Cooling or keeping cold
    • 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
    • H01M10/64—Heating or cooling; Temperature control characterised by the shape of the cells
    • H01M10/643—Cylindrical cells
    • 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
    • H01M10/656—Means for temperature control structurally associated with the cells characterised by the type of heat-exchange fluid
    • H01M10/6567—Liquids
    • 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
    • H01M10/658—Means for temperature control structurally associated with the cells by thermal insulation or shielding
    • 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
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/213—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for cells having curved cross-section, e.g. round or elliptic
    • 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
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H01M50/291—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs characterised by their shape
    • 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
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H01M50/293—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs characterised by the material
    • 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

Definitions

  • This disclosure relates to a process for assembling a thermally insulated battery module in the enclosure of a battery module housing adapted to receive one or more arrays of horizontally mounted cylindrical battery cells.
  • voids are created between adjacent cylindrical battery cells and also between the resulting battery module assembly and the sides of the enclosure.
  • Prefabricated cured silicone foam parts are used to fill voids formed between adjacent cylindrical battery cells and prefabricated cured silicone foam parts and/or a curable silicone foam composition is/are used to fill the voids between the resulting battery module assembly and the sides of the enclosure.
  • Rechargeable battery cells such as lithium-ion batteries (also referred to as Li-ion batteries or LIBs) are increasingly being used in battery modules and/or packs of battery modules for a variety of applications such as for electric-vehicle batteries (EVBs) in electric vehicles (EVs) and hybrid (electric and petrol/diesel) powered vehicles with a view to reducing and ultimately eliminating green-house gas emissions therefrom.
  • EVBs are used to power the propulsion system of electric and hybrid vehicles and as such are designed to give power over sustained periods of time.
  • Lithium-ion battery cells are increasingly becoming the preferred battery cells for said EVBs.
  • individual battery cells (sometimes referred to herein as cells) are aligned in battery modules and a battery pack is constituted by a plurality of electrically interconnected battery modules.
  • the three main constituents in a lithium-ion battery are:
  • lithium ions move from the anode through said electrolyte to the cathode during discharge, and in the reverse direction when being charged.
  • lithium-ion batteries have a potentially hazardous pressurised flammable liquid electrolyte, requiring strict quality control during manufacture and use.
  • An example of a suitable electrolyte is a mixture of organic carbonates, e.g., ethylene carbonate and/or diethyl carbonate containing sources of lithium ions, for example lithium hexafluorophosphate (LiPF 6 ) , lithium hexafluoroarsenate monohydrate (LiAsF 6 ) , lithium perchlorate (LiClO 4 ) , lithium tetrafluoroborate (LiBF 4 ) , and lithium triflate (LiCF 3 SO 3 ) .
  • LiPF 6 lithium hexafluorophosphate
  • LiAsF 6 lithium hexafluoroarsenate monohydrate
  • LiClO 4 lithium perchlorate
  • LiBF 4 lithium tetrafluoroborate
  • LiCF 3 SO 3 lithium triflate
  • EVBs are generally provided in battery packs which are fitted in suitable spaces within the vehicle such as in the car boot or luggage compartment.
  • the EVBs are designed to protect the occupants of a vehicle from the battery modules of lithium-ion batteries in case of a malfunction.
  • the overheating of a first cell is likely to propagate similar occurrences in adjacent cells resulting in multiple cells in a battery module overheating and failing potentially leading to a “thermal runaway” and cell rupture.
  • a thermal runaway is usually initiated by the malfunction of one of the battery cells in a battery module leading to that cell releasing heat abnormally and to a sudden increase in the battery cell’s temperature. Once the temperature exceeds a threshold of, e.g., about 150 °C or thereabouts, the constituents in the malfunctioning cell initiate a self-heating, autocatalytic, thermal decomposition exothermic reaction, where the temperature of the battery increases rapidly, e.g., at a rate of more than 20 °C. per minute, with the temperature of the battery potentially reaching at least 400 °C or even 1000 °C.
  • a threshold e.g., about 150 °C or thereabouts
  • the constituents in the malfunctioning cell initiate a self-heating, autocatalytic, thermal decomposition exothermic reaction, where the temperature of the battery increases rapidly, e.g., at a rate of more than 20 °C. per minute, with the temperature of the battery potentially reaching at least 400 °C or even 1000 °C.
  • thermal runaway In the absence of good insulation and heat dissipation structures in the battery module in which the malfunctioning battery is housed, the thermal energy released consequently heats up neighboring battery cells. resulting in a “thermal runaway” within the battery module.
  • thermal runaway has commenced inside the battery module it cannot be controlled effectively, potentially resulting in combustive exothermic reactions followed by the release of large amounts of flammable electrolyte gas and battery material decomposition gas (e.g., CO 2 , CO, and H 2 ) and possible explosions.
  • flammable electrolyte gas and battery material decomposition gas e.g., CO 2 , CO, and H 2
  • thermal insulation materials are now utilized to minimize EVB thermal runaway propagation.
  • Such thermal insulation materials need to have high levels of flame retardancy, high levels of thermal insulation and to have good temperature resistance. They are also preferred to be lightweight, have good electrical insulation performance are required in this application. Few polymer composites have been proven to provide such properties especially when dealing with temperatures reaching at least 400 °C or even 1000 °C.
  • lithium-ion battery cells are typically produced in three forms as cylindrical cells, as “prismatic” cells which are of a rectangular cuboidal shape and as pouch cells.
  • cylindrical battery cells in horizontal arrays can provide improved packing and hence better energy density as well as reduced cell rotation and enhanced anti-vibration properties.
  • the arrays of cylindrical battery cells are often designed in multiple layers with adjacent layers separated by fluid (e.g., water) cooling manifolds which are provided to extract heat generated by the cylindrical battery cells.
  • fluid e.g., water
  • Such arrangements whilst technically advantageous makes them far more difficult for encapsulants to flow and fill complex voids when cylindrical battery cells are placed horizontally within the battery module, because the horizonal cylindrical battery cell and water-cooling manifold combination makes it far more difficult to ensure encapsulation is achieved without voids being present.
  • coated aerogel felt materials between adjacent battery cells in a battery module to slow down heat transfer has been proposed specifically for battery modules of prismatic cells and pouch cells.
  • said coated aerogel felt materials cause amorphous aerogel silica to disperse into the working environment, requiring more protective equipment during cutting, packaging, storing and transporting processes.
  • these materials provide good initial thermal insulation performance, performance deteriorates dramatically because of a significant decrease in thickness occurring as the pressure within the battery module increases and they are only suitable for use in regular shaped situations so are not practical for cylindrical cells systems.
  • silicone rubber syntactic foams have been proposed for modules of cylindrical battery cells, with a view to trying to fill the irregular voids between the battery cells in a battery module and provide a physical barrier.
  • silicone rubber syntactic foams are silicone rubber foams filled hollow spheres, usually made from glass, which are often referred to as microballoons or cenospheres.
  • the use of said silicone rubber syntactic foams especially for filling irregular voids between cylindrical battery cells in a battery module can itself be problematic because of the presence of the glass spheres which typically render the foams before cure of a sufficiently high viscosity not to be self-levelling.
  • glass spheres are furthermore, easy to break during pre-cure mixing and handling, can easily be suspended on the surface resulting non-homogeneity, potentially requiring additional mixing. Furthermore, such foams are expensive because of the use of glass spheres which is contrary to the needs of the industry and such materials are likely not to meet the requirement of UL 94 V0 type flame retardant tests.
  • a battery module housing having a top and a base and two pairs of opposite sides between the top and the base, where the two pairs of opposite sides between the top and the base, define an enclosure and one pair of the opposite sides comprise electrical mountings adapted to receive a plurality of cylindrical battery cells in a horizontal array in said enclosure;
  • each cylindrical battery cell being mounted between opposite electrical mountings in the one pair of the opposite sides and thereby creating
  • the disclosure further relates to a thermally insulated battery module made via the above process.
  • a battery module housing having a top and a base and two pairs of opposite sides between the top and the base, where the two pairs of opposite sides between the top and the base, define an enclosure and one pair of the opposite sides comprise electrical mountings adapted to receive a plurality of cylindrical battery cells in a horizontal array in said enclosure;
  • each cylindrical battery cell being mounted between opposite electrical mountings in the one pair of the opposite sides and thereby creating
  • the process overcomes the problem of introducing thermal insulation materials into voids (II) (a) in situations where the cylindrical battery cells are mounted horizontally in the enclosure and particularly when the horizontally mounted cylindrical battery cells are divided into layers by the inclusion of one or more fluid cooling manifold (s) separating adjacent layers of cylindrical battery cells.
  • voids (II) (a) are filled (or are prevented from being formed) by the insertion of the prefabricated cured silicone foam parts where voids (II) (a) would otherwise be.
  • Each thermally insulated battery module prepared in accordance the process herein is designed to receive cylindrical battery cells in a horizontal array formation.
  • the cylindrical battery cells are preferably cylindrical lithium-ion battery cells.
  • the battery module housing may be made from any suitable material, for example metals or injection moulded plastics and may also incorporate insert moldings in which the electrical mountings e.g., interconnection strips and terminals are moulded into plastic parts. Small components and/or sub-assemblies may be encapsulated in the housing by any suitable means e.g., by over molding for ease of storage and/or protection.
  • the battery module housing as hereinbefore described may comprise a thinning area or burst plate. This provides a weakened area in the housing which is designed to prevent the inner pressure within the battery module or battery to exceed a predetermined value. If a predetermined pressure value is reached due to the malfunction of one or more cells the weakening or burst plate will be forced open and will enable gases to escape thereby preventing further pressure build up within the battery cell or battery module concerned.
  • the opposite sides of the housing enclosure having opposite electrical mountings are parallel to each other. Once the cylindrical battery cells have been mounted between said opposite electrical mountings they become directly or indirectly electrically interconnected with the other cylindrical battery cells in the module to form a circuit which can be used to charge the cylindrical battery cells and for the charged cylindrical battery cells to function as a power source for the propulsion system of electric and hybrid vehicles.
  • Each battery module as hereinbefore described is electrically interconnected with other battery modules in a battery pack.
  • the modules of each pack may be electrically interconnected in series or in parallel, as required.
  • a thermally insulated battery module as hereinbefore described is required to provide mechanical and electrical interfaces to other battery modules and may also comprise, for the sake of example, cooling mechanisms, temperature monitors, voltage monitors and the like.
  • the housing of a battery module as hereinbefore described is sized and designed to both accommodate a predetermined number of individual battery cells and if desired said other systems.
  • the thermal insulation provided between and around the cylindrical battery cells as defined herein, by the prefabricated cured silicone foam parts described above and utilized to fill voids (II) (a) and optionally (II) (b) and or the curable silicone foam compositions optionally used to fill voids (II) (b) prior to curing are designed to keep a battery cell malfunction localised within said thermally insulated battery module and in the event of a fire to prevent or at least delay the potential for thermal runaway propagation within the whole thermally insulated battery module so as to provide safety protection in the event of the thermal runaway of one battery cell in said thermally insulated battery module.
  • the curable silicone foam compositions are preferably flowable and/or self-leveling.
  • Such a pressure build-up can be up to a pressure equal or greater than ( ⁇ ) 0.9MPa and is caused by a build-up of heated gas (such as CO 2 , CO, and H 2 ) and/or liquid e.g., electrolyte resulting from the failed cell and/or battery module.
  • heated gas such as CO 2 , CO, and H 2
  • liquid e.g., electrolyte resulting from the failed cell and/or battery module.
  • a battery module housing having a top, a base and two pairs of opposite sides between the top and the base.
  • the two pairs of opposite sides between the top and the base define an enclosure.
  • One pair of the opposite sides (which are parallel to each other) comprise opposite electrical mountings adapted to engage (mate with) a plurality of cylindrical battery cells in a horizontal array in said enclosure such that when correctly mounted (e.g., each cylindrical battery cell is connected to the correct negative and positive electrical mounting) an electrical circuit is created.
  • Voids (II) (a) have irregularly shaped cross-sections in view of the cylindrical shape of the battery cells between which they occur.
  • the irregular shapes depend on the number of battery cells each battery cell is adjacent to e.g., dependent on the position and geometry of the of cylindrical battery cells relative to each other.
  • each cylindrical battery cell could have e.g., 3, 5 or even 7 adjacent cylindrical battery cells and the cross-sections of the resulting voids (II) (a) result from their positioning relative to each other.
  • the shape of a void (II) (a) between two adjacent battery cells supported on a horizontal surface would be biconcave.
  • the process disclosed is seeking to overcome the problem of introducing thermal insulation materials into voids (II) (a) in situations where the battery cells are mounted horizontally in the enclosure and when the horizontally mounted battery cells are divided into layers by the inclusion of one or more fluid cooling manifold (s) separating adjacent layers of cylindrical battery cells.
  • voids (II) (a) are filled (or are prevented from being formed) by the insertion of the prefabricated cured silicone foam parts where voids (II) (a) would otherwise be.
  • the shape of the prefabricated cured silicone foam parts may be as required to both fill voids (II) (a) and for ease of insertion. Examples may include:
  • the prefabricated cured silicone material parts may be prepared using any suitable form of fire-retardant silicone compositions such as for example Sylgard TM 170 commercially available from Dow Silicones Corporation of Michigan USA. However, preferably the prefabricated cured silicone material parts are prefabricated cured silicone foam parts made from a suitable curable silicone foam composition as such materials when cured will provide better thermal insulation performance than non-foaming products when battery thermal runaway happens.
  • the curable silicone foam composition may be flowable and/or self-levelling.
  • the prefabricated cured silicone foam parts must:
  • the prefabricated cured silicone foam parts are also preferred to have a low density and are prepared with the intention of having a shape conforming to the shape of the voids into which they are to be positioned. Few polymer foams have been proven to provide all such properties especially when dealing with temperatures reaching at least 400 °C, alternatively 500 °C or even 1000 °C and as such silicone foams are particularly ideal for the purpose concerned.
  • voids (II) (b) between the resulting battery module assembly and the sides of the enclosure are filled via either route (III) (a) or (III) (b) .
  • voids (II) (b) are also provided with prefabricated cured silicone foam parts, and as such there is no need for handling uncured liquid encapsulant material during manufacture of the module.
  • the prefabricated cured silicone foam parts used to fill voids (II) (a) and the prefabricated cured silicone foam parts used to fill voids (II) (b) may be prepared in an analogous fashion using the same or a similar silicone form composition. However, if desired they can be different.
  • the shapes of the prefabricated cured silicone foam parts used to fill void (s) (II) (b) may necessarily be different from those filling voids (II) (a) , for example they may comprise prefabricated cured silicone foam parts having a plano-convex cross-section and or comprise cuboidal shapes.
  • a curable silicone foam composition may be introduced into the void (s) (II) (b) .
  • the enclosure may be filled with a curable silicone foam composition using a foam mixing and /or generating apparatus having one or more foam dispensing tips which are introduced into the enclosure.
  • the foam dispensing tips introduce foam in the enclosure in void (s) (II) (b) in the bottom layer first, allowing the foam to be introduced from the base and gradually filling void (s) (II) (b) from bottom to top thereof.
  • the dispensing tips may be inserting the dispensing tips close to the base and maintaining the tip in the same position until the respective void (II) (b) has been filled after which withdrawing the dispensing tip and enabling the foamed composition to cure.
  • the dispensing tip can be gradually withdrawn from said void by gradually moving the tip toward the top of the enclosure as the void is filled. Once void (s) (II) (b) are filled the foam composition is allowed to cure in (IV) .
  • the curable silicone foam composition used in (III) (b) may be the same composition as is utilized to prepare the prefabricated cured silicone foam parts prepared to fill voids (II) (a) .
  • a base mat of thermally insulating material e.g., a prefabricated cured silicone foam base mat may be initially placed on the base of the enclosure.
  • the base mat may be a fluid cooling manifold and then alternatively a battery cell which sits at rest on the base mat may be electrically mounted and a prefabricated cured silicone foam part may be positioned against at least part of the battery to act as thermal insulation and then mounting of a second battery cell followed by a further prefabricated cured silicone foam parts and repeating the process until a bottom layer of horizontally mounted battery cells thermally insulated using prefabricated cured silicone foam parts has been prepared, allowing for a second layer of battery cells to be mounted and so on.
  • a battery module comprising horizontal battery arrays may comprise two to five 5 layers of fluid cooling manifolds per module.
  • the curable silicone foam composition used in (III) (b) and (III) (c) may preferably be made from a suitable curable silicone foam composition which provides a foam meeting the necessary criteria required for the thermal insulation herein.
  • the curable silicone foam composition utilized will be hydrosilylation (addition) curable and will incorporate one or more chemical and/or physical blowing agents.
  • the foam parts are prepared with the intention of having a shape conforming to the shape of the voids into which they are to be positioned.
  • hydrosilylation (addition) curable silicone foam compositions which may be used to prepare the prefabricated cured silicone foam parts used in the process herein and/or which may be used as the curable silicone foam composition for filling voids (II) (b) typically comprises
  • fire retardant fillers selected from the group of wollastonite, aluminium trihydrate, magnesium hydroxide, halloysite, huntite, hydromagnesite, expandable graphite, zinc borate, mica and/or hydrotalcite; and
  • Such compositions are usually stored in two parts to avoid premature cure.
  • the two parts are generally referred to as part A and part B.
  • Two-part compositions are utilized so that that components (i) polymer, (v) cross-linker, (iii) blowing agent and (ii) catalyst are not all stored together.
  • Part A may comprise components (i) , (ii) and part or all of (iii) and Part B comprises at least components (i) and (v) and typically components (i) and (v) and part of (iii) with part A free of component (v) cross-linker and part B free of component (ii) catalyst.
  • component (iii) blowing agent and Component (iv) the one or more fire retardant fillers may be partially in the part A composition and partially in the part B composition.
  • the two-part curable silicone foam composition may comprise a part A composition of component (i) , component (ii) and component (iii) and a part B composition of component (i) , component (iv) and component (v) such that components (ii) and (iii) are only in the part A composition and components (iv) and (v) are only in the part B composition.
  • the part A and part B compositions are stored for a period of time before use and are mixed to form a foam of the curable silicone foam composition shortly before use, i.e., to make the prefabricated cured silicone foam parts for use in the process herein or to introduce said foam into the voids (II) (b) when reliant on (III) (b) or (III) (c) to insulate the module.
  • the part A and part B of the two-part composition described above may be designed to be mixed together in any suitable ratio dependent on the content and concentration of the ingredients present in each part, for example the two-part composition may be mixed in a Part A : Part B weight ratio of from 15 : 1 to 1 : 10, alternatively from 15 : 1 to 1 : 5, alternatively from 15 : 1 to 1 : 2.5, alternatively from 10 : 1 to 1 : 2.5.
  • the part A : part B ratio is less than 1 : 1, i.e., between 1 : 1 and 1 : 5 when using the embodiment where all filler is added into to the Part B composition and all blowing agent is added to the to the Part A composition.
  • the two parts of the curable silicone foam composition s may be mixed together using a suitable mixing means e.g., each part may be pumped from storage to a suitable mixing and dispensing unit, e.g., a static mixer and then after mixing is transported to a suitable dispensing means.
  • a suitable mixing and dispensing unit e.g., a static mixer
  • foaming will commence.
  • the foaming composition may be transported to the dispensing head by a pump to control the cell size of the silicone elastomer foam generated.
  • the dispensing head may be controlled by using a pre-programmed or programable robot dispensing head which can be used to apply the composition to the target module.
  • the dispensing head may, for example, be programed to apply an optimized amount of foam at a pre-determined dispensing flow rate.
  • the foam composition may be mechanically blown or may comprise chemical and/or physical blowing agents.
  • suitable physical blowing agents including those which are non-flammable and/or inert gas at 0°C (zero °C) may be utilized.
  • the curable silicone foam composition s as described herein preferably produce open cell and/or closed cell foams.
  • the density may be measured by any suitable process such as via the Archimedes principle, using a balance and density kit, and following standard instructions associated therewith.
  • a suitable balance is a Mettler-Toledo XS205DU balance with density kit.
  • a closed cell foam it may have a density of from 0.01 grams per cubic centimeter g/cm 3 to 5 g/cm 3 , alternatively from 0.05 g/cm 3 to 2.5 g/cm 3 alternatively from 0.1 g/cm 3 to 2.0 g/cm 3 , alternatively from 0.1 g/cm 3 to 1.5 g/cm 3 .
  • the average pore size can be determined via any suitable process such as in accordance with ATSM process D3576-15 optionally with the following modifications:
  • the curable silicone foam composition s which are preferred herein generally have pores that are uniform in size and/or shape.
  • the foam has an average pore size of between 0.001mm and 5mm, alternatively between 0.001mm and 2.5mm, alternatively between 0.001mm and 1mm, alternatively between 0.001mm and 0.5mm, alternatively between 0.001mm and 0.25mm, alternatively between 0.001mm and 0.1mm, and alternatively between 0.001mm and 0.05mm.
  • An example of a suitable curable silicone foam composition which may be utilized to prepare the prefabricated cured silicone foam parts used in the process herein and/or which may be used as the curable silicone foam composition for filling voids (II) (b) is a self-levelling, non-syntactic silicone foam composition comprising the following components:
  • fire retardant fillers selected from the group of wollastonite, aluminium trihydrate, magnesium hydroxide, halloysite, huntite, hydromagnesite, expandable graphite, zinc borate, mica and/or hydrotalcite; and
  • a cross-linker comprising an organosilicon compound having at least two, alternatively at least three silicon bonded hydrogen groups per molecule.
  • silicone rubber syntactic foams are silicone rubber foams filled with hollow spheres, usually made from glass, which are often referred to as microballoons or cenospheres.
  • a non-syntactic silicone foam composition means that the composition does not contain said hollow spheres, usually made from glass, which are often referred to as microballoons or cenospheres.
  • Component (i) of the self-levelling, non-syntactic silicone foam composition used in the process described herein is one or more polydiorganosiloxanes having at least two unsaturated groups per molecule, alternatively at least three unsaturated groups per molecule selected from alkenyl and/or alkynyl groups;
  • the unsaturated groups of component (i) may be terminal, pendent, or in both locations in component (i) .
  • the unsaturated group may be an alkenyl group and/or an alkynyl group.
  • Alkenyl is exemplified by, but not limited to, vinyl, allyl, 2-methyl-allyl, propenyl, and hexenyl groups.
  • Alkenyl groups may have 2 to 30, alternatively 2 to 24, alternatively 2 to 20, alternatively 2 to 12, alternatively 2 to 10, and alternatively 2 to 6 carbon atoms.
  • Alkynyl may be exemplified by, but not limited to, ethynyl, propynyl, and butynyl groups.
  • Alkynyl groups may have 2 to 30, alternatively 2 to 24, alternatively 2 to 20, alternatively 2 to 12, alternatively 2 to 10, and alternatively 2 to 6 carbon atoms.
  • Component (i) has multiple units of the formula (I) :
  • each R is independently selected from an aliphatic hydrocarbyl, aromatic hydrocarbyl, or organyl group (that is any organic substituent group, regardless of functional type, having one free valence at a carbon atom) .
  • Saturated aliphatic hydrocarbyls are exemplified by, but not limited to alkyl groups such as methyl, ethyl, propyl, n-butyl, t-butyl, pentyl, hexyl, octyl, undecyl, and octadecyl and cycloalkyl groups such as cyclohexyl.
  • Unsaturated aliphatic hydrocarbyls are exemplified by, but not limited to the alkenyl groups and alkynyl groups described above.
  • Aromatic hydrocarbon groups are exemplified by, but not limited to, phenyl, tolyl, xylyl, benzyl, styryl, and 2-phenylethyl.
  • Organyl groups are exemplified by, but not limited to, halogenated alkyl groups (excluding fluoro containing groups) such as chloromethyl and 3-chloropropyl; nitrogen containing groups such as amino groups, amido groups, imino groups, imido groups; oxygen containing groups such as polyoxyalkylene groups, carbonyl groups, alkoxy groups and hydroxyl groups. Further organyl groups may include sulfur containing groups, phosphorus containing groups, boron containing groups. The subscript “a” is 0, 1, 2 or 3.
  • Siloxy units may be described by a shorthand (abbreviated) nomenclature, namely - "M, " “D, “ “T, “ and “Q” , when R is a methyl group.
  • the polydiorganosiloxane of component (i) is substantially linear but may however, there can be some branching due to the presence of T units (as previously described) within the molecule, hence the average value of a in structure (I) is about 2.
  • Examples of typical groups on component (i) include mainly alkenyl, alkynyl, alkyl, and/or aryl groups, alternatively alkenyl, alkyl, and/or aryl groups.
  • the groups may be in pendent position (on a D or T siloxy unit) or may be terminal (on an M siloxy unit) .
  • the silicon-bonded organic groups attached to component (i) other than the unsaturated groups are typically selected from alkyl groups having from 1 to 10 carbon atoms such as methyl, ethyl, propyl, n-butyl, t-butyl, pentyl, hexyl, octyl, and monovalent aromatic hydrocarbon groups, which typically contain from 6 to 12 carbon atoms, which are unsubstituted or substituted with the groups that do not interfere with curing of this inventive composition, such as halogen atoms.
  • Preferred species of the silicon-bonded organic groups are, for example, alkyl groups such as methyl, ethyl, and propyl; and aryl groups such as phenyl.
  • Component (i) may be selected from polydimethylsiloxanes, alkylmethylpolysiloxanes, alkylarylpolysiloxanes or copolymers thereof (where reference to alkyl means an alkyl group having two or more carbons) containing e.g. alkenyl and/or alkynyl groups and may have any suitable terminal groups, for example, they may be trialkyl terminated, alkenyldialkyl terminated alkynyldialkyl terminated or may be terminated with any other suitable terminal group combination providing each polymer contains at least two unsaturated groups selected from alkenyl and alkynyl groups per molecule. In one embodiment the terminal groups of such a polymer does not contain any silanol terminal groups.
  • component (i) may, for the sake of example, be:
  • dialkylalkenyl terminated polydimethylsiloxane e.g. dimethylvinyl terminated polydimethylsiloxane
  • a dialkylalkenyl terminated dimethylmethylphenylsiloxane e.g.
  • dimethylvinyl terminated dimethylmethylphenylsiloxane a trialkyl terminated dimethylmethylvinyl polysiloxane; a dialkylvinyl terminated dimethylmethylvinyl polysiloxane copolymer; a dialkylvinyl terminated methylphenyl polysiloxane, a dialkylalkenyl terminated methylvinylmethylphenyl polysiloxane; a dialkylalkenyl terminated methylvinyldiphenyl polysiloxane; a dialkylalkenyl terminated methylvinyl methylphenyl dimethyl polysiloxane; a trimethyl terminated methylvinyl methylphenyl polysiloxane; a trimethyl terminated methylvinyl diphenyl polysiloxane; or a trimethyl terminated methylvinyl methylphenyl dimethyl polysiloxane and may be linear or branched but is typically largely
  • the component (i) is typically a flowable liquid having a viscosity of from 100 to 20,000 mPa. s at 25°C mPa. s, alternatively from 300 to 12000 mPa. s, at 25 °C. Viscosity may be measured at 25 °C using either a rotational viscometer with spindle LV-3 (designed for viscosities in the range between 200-400,000 mPa. s) or a rotational viscometer with spindle LV-1 (designed for viscosities in the range between 15 -20,000mPa. s) for viscosities less than 1000mPa. s at a rate of 100 revolutions per minute (rpm) .
  • Component (i) may be present in the composition in an amount of from 30 to 70 wt. %of the composition, alternatively 30 to 65 wt. %of the composition.
  • Component (ii) of the self-levelling, non-syntactic silicone foam composition which may be used to prepare the prefabricated cured silicone foam parts used in the process herein and/or which may be used as the curable silicone foam composition for filling voids (II) (b) is a catalyst comprising or consisting of a platinum group metal or a compound or complex thereof.
  • platinum group it is meant ruthenium, rhodium, palladium, osmium, iridium and platinum. Platinum and platinum compounds or complexes are preferred due to the high activity level of these catalysts in hydrosilylation reactions.
  • Examples of preferred hydrosilylation catalysts (ii) are platinum based catalysts, for example, platinum black, platinum oxide (Adams catalyst) , platinum on various solid supports, chloroplatinic acids, e.g. hexachloroplatinic acid (Pt oxidation state IV) (Speier catalyst) , chloroplatinic acid in solutions of alcohols e.g. isooctanol or amyl alcohol (Lamoreaux catalyst) , and complexes of chloroplatinic acid with ethylenically unsaturated compounds such as olefins and organosiloxanes containing ethylenically unsaturated silicon-bonded hydrocarbon groups, e.g.
  • platinum based catalysts for example, platinum black, platinum oxide (Adams catalyst) , platinum on various solid supports, chloroplatinic acids, e.g. hexachloroplatinic acid (Pt oxidation state IV) (Speier catalyst) , chloroplatinic
  • Soluble platinum compounds that can be used include, for example, the platinum-olefin complexes of the formulae (PtCl 2 . (olefin) 2 and H (PtCl 3 . olefin) , preference being given in this context to the use of alkenes having 2 to 8 carbon atoms, such as ethylene, propylene, isomers of butene and of octene, or cycloalkanes having 5 to 7 carbon atoms, such as cyclopentene, cyclohexene, and cycloheptene.
  • Platinum catalysts are, for the sake of example a platinum-cyclopropane complex of the formula (PtCl 2 C 3 H 6 ) 2 , the reaction products of hexachloroplatinic acid with alcohols, ethers, and aldehydes or mixtures thereof, or the reaction product of hexachloroplatinic acid and/or its conversion products with vinyl-containing siloxanes such as methylvinylcyclotetrasiloxane in the presence of sodium bicarbonate in ethanolic solution –.
  • Platinum catalysts with phosphorus, sulfur, and amine ligands can be used as well, e.g. (Ph 3 P) 2 PtCl 2 ; and complexes of platinum with vinylsiloxanes, such as sym-divinyltetramethyldisiloxane.
  • a platinum-containing catalyst which is obtained by a process comprising reacting chloroplatinic acid with an aliphatically unsaturated organosilicon compound, such as divinyltetramethyldisiloxane;
  • alkene-platinum-silyl complexes as described in US Pat. No. 6,605,734 such as (COD) Pt (SiMeCl 2 ) 2 where “COD” is 1, 5-cyclooctadiene; and/or
  • (v) Karstedt's catalyst, a platinum divinyl tetramethyl disiloxane complex typically containing about 1 wt. %of platinum typically in a vinyl siloxane polymer. Solvents such as toluene and the like organic solvents have been used historically as alternatives but the use of vinyl siloxane polymers by far the preferred choice. These are described in US3,715,334 and US3,814,730.
  • component (ii) may be selected from co-ordination compounds of platinum.
  • hexachloroplatinic acid and its conversion products with vinyl-containing siloxanes, Karstedt's catalysts and Speier catalysts are preferred.
  • the hydrosilylation catalyst (ii) is present in the total composition in a catalytic amount, i.e., an amount or quantity sufficient to promote a reaction or curing thereof at desired conditions. Varying levels of the hydrosilylation catalyst (ii) can be used to tailor reaction rate and cure kinetics.
  • the catalytic amount of the hydrosilylation catalyst (ii) is generally between 0.01 ppm, and 10,000 parts by weight of platinum-group metal, per million parts (ppm) , based on the combined weight of the composition components (i) and (v) ; alternatively, between 0.01 and 5000 ppm; alternatively, between 0.01 and 3,000 ppm, and alternatively between 0.01 and 1,000 ppm.
  • the catalytic amount of the catalyst may range from 0.01 to 1,000 ppm, alternatively 0.01 to 750 ppm, alternatively 0.01 to 500 ppm and alternatively 0.01 to 100 ppm of metal based on the weight of the composition.
  • the ranges may relate solely to the metal content within the catalyst or to the catalyst altogether (including its ligands) as specified, but typically these ranges relate solely to the metal content within the catalyst.
  • the catalyst may be added as a single species or as a mixture of two or more different species.
  • the amount of catalyst present will be within the range of from 0.001 to 3.0 wt. %of the composition, alternatively within the range of from 0.1–1.5 wt. %of the composition, alternatively from 0.1–1.0 wt. %, alternatively 0.1 to 0.5 wt. %, of the composition.
  • Component (iii) of the self-levelling, non-syntactic silicone foam composition which may be used to prepare the prefabricated cured silicone foam parts used in the process herein and/or which may be used as the curable silicone foam composition for filling voids (II) (b) is a chemical blowing agent, a physical blowing agent or a mixture of a chemical blowing agent and a physical blowing agent.
  • component (iii) comprises a chemical blowing agent
  • it comprises one or more hydroxyl-containing blowing agents which will react with the cross-linker (v) in the presence of component (ii) the catalyst.
  • component (iii) is a chemical blowing agent, comprising one or more hydroxyl-containing blowing agents
  • each hydroxyl-containing blowing agent has at least one OH group, alternatively at least two OH groups, and alternatively three or more OH groups.
  • the OH group (s) can react with the Si-H groups of component (v) , thereby generating hydrogen gas, which is relied upon to generate the foam.
  • Each hydroxyl-containing blowing agent may be a suitable alcohol.
  • These may be selected from aliphatic organic alcohols having from 1 to 12 carbon atoms such as low molecular weight alcohols including, but are not limited to, methanol, ethanol, propanol, isopropanol, and the like or alternatively, benzyl alcohol.
  • a hydroxyl-containing blowing agent may be a diol.
  • suitable diols include, but are not limited to, methylene glycol, ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, butane diol, bisphenol A, 1, 4-butanediol, 1, 3-propanediol, 1, 5-pentanediol, 1, 7-heptanediol, 1, 2-hexanediol, triethylene glycol, tripropylene glycol neopentyl glycol, and combinations thereof.
  • a hydroxyl-containing blowing agent may be a triol.
  • component (iii) when a hydroxyl-containing blowing agent is selected from the group of low-boiling alcohols.
  • a hydroxyl-containing blowing agent is selected from the group of low-boiling alcohols.
  • Such alcohols generally have a boiling point lower than about 120 °C.
  • the alcohols may or may not be anhydrous, but anhydrous (containing less than 1 wt. %) water based on weight of alcohol is generally preferred.
  • Other suitable blowing agents are described in US4550125, US6476080, and US20140024731, which are incorporated herein by reference.
  • the chemical blowing agent may be selected from the group of Si-OH polymers.
  • component (iii) is selected from the group consisting of organosilanes and organosiloxanes having at least one silanol (Si-OH) group.
  • Such compounds can have structures similar to those for the polymers described above for component (i) .
  • Suitable OH-functional compounds include dialkyl siloxanes, such as OH-terminated dimethyl siloxanes.
  • Such siloxanes may have a relatively low viscosity, such as about 15 to about 20,000mPa. s, about 15 to about 10,000mPa. s, about 15 to about 5,000 mPa. s, about 15 to about 1,000 mPa. s, or about 15 to about 100 mPa. s. measured at 25°C. Viscosity may be measured at 25 °C using either a rotational viscometer with spindle LV-3 (designed for viscosities in the range between -200-400,000mPa.
  • component (iii) may comprise a physical liquid blowing agent.
  • component (iii) is a physical liquid blowing agent
  • said physical liquid blowing agent is tailored to undergo a phase change at the temperature of application.
  • component (iii) is a physical blowing agent
  • said phase change at the temperature of application is the main source for the gas that leads to the formation of the foam by replacing all or most of the hydrogen gas generated when using a chemical blowing agent.
  • component (iii) is a physical blowing agent
  • the physical blowing agent chosen is selected in accordance with its boiling point such that it undergoes a phase change from a liquid to a gaseous state during exposure to atmospheric pressure and the temperature of the cure process, e.g. a temperature less than or equal to 10°C, alternatively less than or equal to 20°C, alternatively less than or equal to 30°C, alternatively less than or equal to 40°C, alternatively less than or equal to 50°C, alternatively less than or equal to 60°C, alternatively less than or equal to 70°C, alternatively less than or equal to 80°C, alternatively less than or equal to 90°C, alternatively less than or equal to 100°C.
  • the physical blowing agent chosen may have a boiling point of between 10 and 30°C, i.e., such that it undergoes a phase change from a liquid to a gaseous state during exposure to atmospheric pressure within this temperature range.
  • the amount of physical blowing agent utilized, when component (iii) is a physical blowing agent, can vary depending on the desired outcome. For example, the amount of physical blowing agent can be varied to tailor final foam density and foam rise profile of the resulting thermal insulation.
  • Useful physical blowing agents include hydrocarbons, such as pentane, hexane, halogenated, more particularly chlorinated and/or fluorinated, hydrocarbons, for example methylene chloride, chloroform, trichloroethane, chlorofluorocarbons, hydrochlorofluorocarbons (HCFCs) , ethers, ketones and esters, for example methyl formate, ethyl formate, methyl acetate or ethyl acetate, in liquid form or air, nitrogen or carbon dioxide as gases.
  • hydrocarbons such as pentane, hexane, halogenated, more particularly chlorinated and/or fluorinated
  • hydrocarbons for example methylene chloride, chloroform, trichloroethane, chlorofluorocarbons, hydrochlorofluorocarbons (HCFCs) , ethers, ketones and esters, for example methyl formate, ethyl formate,
  • the physical blowing agent comprises a compound selected from the group consisting of propane, butane, isobutane, isobutene, isopentane, dimethylether or mixtures thereof. In many embodiments, the blowing agent comprises a compound that is inert.
  • the physical blowing agent comprises a hydrofluorocarbon (HFC) .
  • HFC hydrofluorocarbon
  • “Hydrofluorocarbon” and “HFC” are interchangeable terms and refer to an organic compound containing hydrogen, carbon, and fluorine. The compound is substantially free of halogens other than fluorine.
  • HFCs include aliphatic compounds such as 1, 1, 1, 3, 3-pentafluoropropane, 1, 1, 1, 3, 3-pentafluorobutane, 1-fluorobutane, nonafluorocyclopentane, perfluoro-2-methylbutane, 1-fluorohexane, perfluoro-2, 3-dimethylbutane, perfluoro-1, 2-dimethylcyclobutane, perfluorohexane, perfluoroisohexane, perfluorocyclohexane, perfluoroheptane, perfluoroethylcyclohexane, perfluoro- 1, 3-dimethyl cyclohexane, and perfluorooctane; as well as aromatic compounds such as fluorobenzene, 1, 2-difluorobenzene; 1, 4-difluorobenzene, 1, 3-difluorobenzene; 1, 3, 5-trifluorobenzene; 1,
  • compounds such as 1, 1, 1, 3, 3-pentafluoropropane and 1, 1, 1, 3, 3-pentafluorobutane may be preferred due to their increasing availability and ease of use, with 1, 1, 1, 3, 3-pentafluorobutane having a higher boiling point than 1, 1, 1, 3, 3-pentafluoropropane which may be useful in certain applications.
  • HFCs having a boiling point higher than 30 °C, such as 1, 1, 1, 3, 3-pentafluorobutane may be desirable because they do not require liquefaction during foam processing.
  • component (iii) when component (iii) is a physical blowing agent, component (iii) comprises 1, 1, 1, 3, 3-pentafluoropropane.
  • component (iii) of the self-levelling, non-syntactic silicone foam composition may alternatively be a mixture of a chemical blowing agent as described above and of a physical blowing agent as described above.
  • Component (iii) is typically present in the composition in an amount of from 2 to about 20 wt. %of the composition, alternatively from 2 to about 15 wt. %of the composition.
  • Component (iv) of the self-levelling, non-syntactic silicone foam composition which may be used to prepare the prefabricated cured silicone foam parts used in the process herein and/or which may be used as the curable silicone foam composition for filling voids (II) (b) is one or more fire retardant fillers selected from the group of wollastonite, aluminium trihydrate, magnesium hydroxide, halloysite, huntite, hydromagnesite, expandable graphite, zinc borate, mica and/or hydrotalcite.
  • the fire-retardant fillers may optionally also comprise fumed silica.
  • the fire-retardant fillers may optionally be surface treated with a treating agent.
  • the treating agents used may be selected from one or more of, for example, organosilanes, polydiorganosiloxanes, or organosilazanes, hexaalkyl disilazane, short chain siloxane diols, a fatty acid or a fatty acid ester such as a stearate to render one or more of the fillers (s) hydrophobic and therefore easier to handle and obtain a homogeneous mixture with the other components.
  • liquid hydroxyl-terminated polydiorganosiloxane containing an average from 2 to 20 repeating units of diorganosiloxane in each molecule which may optionally contain fluoro groups and or fluoro containing groups, if desired, hexaorganodisiloxane, hexaorganodisilazane, and the like.
  • Component (iv) the one or more fire retardant fillers selected from the group of wollastonite, aluminium trihydrate, magnesium hydroxide, halloysite, huntite, hydromagnesite, expandable graphite, zinc borate, mica and/or hydrotalcite, may be present in any suitable amount for example from 10 to 50 wt. %of the composition.
  • Component (v) of the self-levelling, non-syntactic silicone foam composition which may be used to prepare the prefabricated cured silicone foam parts used in the process herein and/or which may be used as the curable silicone foam composition for filling voids (II) (b) is a cross-linker comprising an organosilicon compound having at least two, alternatively at least three silicon bonded hydrogen groups per molecule.
  • Component (v) operates as a cross-linker for curing component (i) , by the addition reaction of the silicon-bonded hydrogen atoms with the unsaturated groups in component (i) catalysed by component (ii) described above.
  • Component (v) normally contains three or more silicon-bonded hydrogen atoms so that the hydrogen atoms of this component can sufficiently react with the unsaturated groups of component (i) to form a network structure therewith and thereby cure the composition. Some or all of Component (v) may alternatively have two silicon bonded hydrogen atoms per molecule when component (i) has greater than (>) 2 unsaturated groups, alternatively alkenyl groups per molecule.
  • Component (v) may be a siloxane e.g., an organohydrogensiloxane or a silane e.g., a monosilane, disilane, trisilane, or polysilane providing each molecule has at least two, alternatively at least three Si-H groups per molecule.
  • the silicon-bonded hydrogen atoms can be located at terminal, pendant, or at both terminal and pendant positions.
  • Cyclosilanes and cyclosiloxanes typically have from 3 to 12 silicon atoms, alternatively from 3 to 10 silicon atoms, alternatively from 3 to 4 silicon atoms.
  • component (v) when component (v) is a siloxane it may comprise an organohydrogensiloxane, which can be a disiloxane, trisiloxane, or polysiloxane.
  • the organohydrogensiloxane may comprise any combination of M, D, T and/or Q siloxy units, so long as component (v) includes at least two silicon-bonded hydrogen atoms.
  • These siloxy units can be combined in various manners to form cyclic, linear, branched and/or resinous (three-dimensional networked) structures.
  • Component (v) may be monomeric, polymeric, oligomeric, linear, branched, cyclic, and/or resinous depending on the selection of M, D, T, and/or Q units.
  • component (v) examples include but are not limited to:
  • trimethylsiloxy-terminated methylhydrogenpolysiloxane trimethylsiloxy-terminated polydimethylsiloxane-methylhydrogensiloxane, dimethylhydrogensiloxy-terminated dimethylsiloxane-methylhydrogensiloxane copolymers, dimethylsiloxane-methylhydrogensiloxane cyclic copolymers, copolymers composed of (CH 3 ) 2 HSiO 1/2 units and SiO 4/2 units, copolymers composed of (CH 3 ) 3 SiO 1/2 units, (CH 3 ) 2 HSiO 1/2 units, and SiO 4/2 units; and copolymers containing (CH 3 ) 2 HSiO 1/2 units and (R 2 Z) d (R 3 ) e SiO (4-d-e) /2 as described above.
  • viscosity of this component is not specifically restricted, it may typically be from 5 -1,000 mPa. s at 25°C, alternatively 5 -500 mPa. s at 25°C, alternatively 5 -100 mPa. s at 25°C, alternatively 5 -50mPa. s at 25°C, alternatively 5-20 mPa. s at 25°C using a rotational viscometer with spindle LV-1 (designed for viscosities in the range between 15 -20,000mPa.
  • the cross-linker is selected from one or more of said copolymers composed of (CH 3 ) 2 HSiO 1/2 units and SiO 4/2 units,
  • Copolymers composed of (CH 3 ) 3 SiO 1/2 units, (CH 3 ) 2 HSiO 1/2 units, and SiO 4/2 units; and copolymers containing (CH 3 ) 2 HSiO 1/2 units and (R 2 Z) d (R 3 ) e SiO (4-d-e) /2 as described above, said copolymers may be or are silicone resins. This is preferred because the high proportion of Si-H groups leads to an increased cross-link density in the final cured product.
  • Component (v) is typically added in an amount such that the molar ratio of the silicon-bonded hydrogen atoms in component (v) to that of all unsaturated groups in the composition and the number of -OH groups in component (iii) , when a chemical blowing agent, is from 0.5: 1 to 20: 1; alternatively of from 0.5 : 1 to 5 : 1, alternatively from 0.6 : 1 to 3 : 1. When this ratio is less than 0.5: 1, a well-cured composition will not be obtained. When the ratio exceeds 20: 1, there is a tendency for the hardness of the cured composition to increase when heated.
  • each group mentioned in the above ratio e.g., silicon-bonded hydrogen (Si-H) content of organohydrogenpolysiloxane (v) may be determined using quantitative infra-red analysis in accordance with ASTM E168, if desired.
  • the alkenyl and/or alkynyl content of polymer (i) is determined using quantitative infra-red analysis in accordance with ASTM E168.
  • component (v) is present in the composition in an amount of from 0.5 to10 wt. %of the total composition which amount is determined dependent on the required molar ratio of the total number of the silicon-bonded hydrogen atoms in component (v) to the total number of all alkenyl and alkynyl groups in component (i) and the amount of hydroxyl groups in component (iii) when a chemical blowing agent.
  • the composition may include one or more optional additives but the total weight % (wt. %) of the composition is 100 wt. %. It was found that utilizing a component (i) having a low viscosity of from 100 to 20,000 mPa. s at 25°C mPa. s, alternatively from 200 to 2000 mPa. s, at 25 °C increases the relative unsaturation content per molecule and as such enhances the cross-link density of the cured product. This is particularly noted when component (v) the cross-linker is resinous and has numerous terminal groups comprising Si-H groups per molecule.
  • the self-levelling, non-syntactic silicone foam composition which may be used to prepare the prefabricated cured silicone foam parts used in the process herein and/or which may be used as the curable silicone foam composition for filling voids (II) (b) may optionally further comprise additional ingredients or components (hereafter referred to as “additives” ) .
  • additional ingredients include, but are not limited to, foam stabilizers, inhibitors; surfactants; other stabilizers e.g., heat stabilizers; adhesion promoters; colorants, including dyes and pigments; antioxidants; carrier fluids; heat stabilizers; flame retardants; flow control additives and/or non-reinforcing (sometimes referred to as extending) fillers.
  • the one or more additives can be present in a suitable wt. %of the composition.
  • the additive may be present in an amount of up to about 10 or even 15 wt. %based on the understanding that the total wt. %of the composition is 100 wt. %.
  • One of skill in the art can readily determine a suitable amount of additive depending, for example, on the type of additive and the desired outcome. Certain optional additives are described in greater detail below.
  • the composition may further comprise an organopolysiloxane resin ( “resin” ) as a resin foam stabilizer.
  • the resin has a branched or a three-dimensional network molecular structure.
  • the organopolysiloxane resin may be in a liquid or in a solid form, optionally dispersed in a carrier, which may solubilize and/or disperse the resin therein.
  • the organopolysiloxane resin may be exemplified by an organopolysiloxane that comprises only T units, an organopolysiloxane that comprises T units in combination with other siloxy units (e.g., M, D, and/or Q siloxy units) , or an organopolysiloxane comprising Q units in combination with other siloxy units (i.e., M, D, and/or T siloxy units) .
  • the resin comprises T and/or Q units.
  • Specific examples are alkenylated silsesquioxanes or MQ resins e.g., vinyl terminated silsesquioxanes or MQ resins.
  • the self-levelling, non-syntactic silicone foam composition may further comprise a hydrosilylation reaction inhibitor to inhibit the cure of the composition.
  • Hydrosilylation reaction inhibitors are used, when required, to prevent or delay the hydrosilylation reaction curing process especially during storage.
  • the optional hydrosilylation reaction inhibitors of platinum based catalysts are well known in the art and include hydrazines, triazoles, phosphines, mercaptans, organic nitrogen compounds, acetylenic alcohols, silylated acetylenic alcohols, maleates, fumarates, ethylenically or aromatically unsaturated amides, ethylenically unsaturated isocyanates, olefinic siloxanes, unsaturated hydrocarbon monoesters and diesters, conjugated ene-ynes, such as 3-methyl-3-penten-1-yne, 3, 5-dimethyl-3-hexen-1-yne hydroperoxides, nitriles, and diaziridines.
  • Alkenyl-substituted siloxanes as described in US3989667 may be used, of which cyclic methylvinylsiloxanes such as 1, 3, 5, 7-tetramethyl-1, 3, 5, 7-tetravinylcyclotetrasiloxane, 1, 3, 5, 7-tetramethyl-1, 3, 5, 7-tetrahexenylcyclotetrasiloxane, are preferred.
  • One class of known hydrosilylation reaction inhibitor includes the acetylenic compounds disclosed in US3445420.
  • Acetylenic alcohols such as 2-methyl-3-butyn-2-ol constitute a preferred class of inhibitors that will suppress the activity of a platinum-containing catalyst at 25 °C.
  • Compositions containing these inhibitors typically require heating at temperature of 70 °C or above to cure at a practical rate.
  • acetylenic alcohols and their derivatives include 3-methyl-1-butyn-3-ol, 1-ethynyl-1-cyclohexanol (ETCH) , 2-methyl-3-butyn-2-ol, 3-butyn-1-ol, 3-butyn-2-ol, propargyl alcohol, 1-phenyl-2-propyn-1-ol, 3, 5-dimethyl-1-hexyn-3-ol, 3-phenyl-1-butyn-3-ol, 1-ethynylcyclopentanol, 3-methyl-1-penten-4-yn-3-ol, and mixtures thereof.
  • Derivatives of acetylenic alcohol may include those compounds having at least one silicon atom.
  • inhibitor concentrations as low as 1 mole of inhibitor per mole of the metal of catalyst will in some instances impart satisfactory storage stability and cure rate. In other instances, inhibitor concentrations of up to 500 moles of inhibitor per mole of the metal of catalyst are required.
  • the optimum concentration for a given inhibitor in a given composition is readily determined by routine experimentation. Dependent on the concentration and form in which the inhibitor selected is provided/available commercially, when present in the composition, the inhibitor is typically present in an amount of from 0.0125 to 10 wt. %of the composition.
  • the part A composition might also include one or more of the aforementioned optional components such as inhibitor (depending on the choice of inhibitor) , pigments or colorants and/or an MQ resin foam stabilizer.
  • the part B blend composition might also include one or more of the aforementioned optional components such inhibitor (depending on the choice of inhibitor) , pigments or colorants and/or an MQ resin foam stabilizer. Alternatively, a proportion of said additives may be present in each both the part A and part B composition if desired.
  • the self-levelling, non-syntactic silicone foam composition may be of any suitable viscosity where the composition is able to self-level in the module subsequent to being dispensed therein; for example, the composition may have a viscosity of from 500 to 20,000mPa. s at 25°C, alternatively 500 to 15,000mPa. s at 25°C, 500 to 10,000mPa. s at 25°C, alternatively 500 to 5,000mPa. s at 25°C.
  • the viscosity measurements of the final composition after parts A and B had been mixed were carried out in accordance with ASTM D1084 using a Brookfield spindle LV-3 at 100 rpm.
  • the viscosity measurement is taken prior to or at the start of the cure of the self-levelling, non-syntactic silicone foam composition, or immediately after dispensing.
  • the viscosity of the final composition after parts A and B have been mixed may be carried out in accordance with ASTM D1084 using a Brookfield spindle LV-3 at 100rpm.
  • One or more components of the self-levelling, non-syntactic silicone foam composition may have a viscosity which is greater than the overall viscosity of the composition, providing when all components and additives are mixed together the viscosity of the final composition is within the range specified.
  • the viscosity of the self-levelling, non-syntactic silicone foam composition is greater than (>) the viscosity of each individual component present.
  • any suitable foaming and application process may be used in the manufacture of the prefabricated cured silicone foam parts.
  • the prefabricated cured silicone foam parts may be prepared by molding e.g., introducing a foamed composition into a mold of a desired shape and allowing the composition to cure. Cure may take place at room temperature or at an elevated temperature if required.
  • a release agent may be included in the composition to ensure release from the mold after curing but preferably when required the mold surface may be coated with a suitable release agent e.g., with Teflon coating layer.
  • the resulting prefabricated cured silicone foam parts may be used to fill voids (II) (a) and (II) (b) in the assembly of thermally insulated battery module in the enclosure of a battery module housing as described herein.
  • Other processes for producing the prefabricated cured silicone foam parts may include, injection molding, extrusion molding, pressing and/or casting depending on the suitability of the foam composition to be used and its preferred process/temperature of curing and the like.
  • thermally insulated battery modules described herein may be used as part of battery packs.
  • Each thermally insulated battery module as hereinbefore described is electrically interconnected with other battery modules in a battery pack.
  • the modules in the pack may be electrically connected in any suitable manner, e.g., in series or in parallel, as required.
  • a battery pack comprising at least one battery module as described above, alternatively two or more battery modules as described above.
  • Battery pack designs for e.g., electric-vehicle batteries are complex but incorporate a combination of several simple mechanical and electrical component systems which perform the basic required functions of the pack.
  • the battery packs therefore additionally comprise one or more of the following:
  • heat dissipation members which are disposed between cylindrical battery cells, and at least one heat exchange member. whereby heat generated from the cylindrical battery cells during the charge and discharge of the cylindrical battery cells is removed by the heat exchange member.
  • the heat dissipation members may be made from a suitable thermally conductive material exhibiting high thermal conductivity and the heat exchange member is provided with one or more coolant channels for allowing a coolant such as a liquid or a gas to flow there;
  • Control systems to keep the thermally insulated battery modules/cells within a predefined specified operating range e.g., for monitoring the battery status and controlling energy flows and to protect them from abuse;
  • a battery pack as described above has to fit the space provided in the article for which it is providing power, e.g., a vehicle. This may dictate the shape of the battery modules and indeed individual cells and consequently the shape and/or form of the battery cells in a module and consequently the thermal insulation therebetween. In some designs the battery pack forms part of the outer case of the end-product. The colours and textures of the battery pack housing must match the rest of the product in such cases. Hence, designs of this type may be required to incorporate a mechanical connection means to hold the battery pack in place. Said mechanical connection means (e.g., a latch) , as well as electrical terminals and the like, must interface with other parts of the article to be powered by the battery pack. Any suitable material may be used for this mechanical connection means, for example acrylonitrile butadiene styrene (ABS) polymers may be utilized.
  • ABS acrylonitrile butadiene styrene
  • Figs. 1a to 1h is a step-by-step depiction of a first embodiment of the process for assembling a thermally insulated battery module as described herein;
  • Fig. 2a to 2h is a step-by-step depiction of a second embodiment of the process for assembling a thermally insulated battery module as described herein;
  • Fig. 3a to 3i is a step-by-step depiction of a third embodiment of the process for assembling a thermally insulated battery module as described herein.
  • Fig. 4a to 4d are photographs of molded parts the cross-sections of which are depicted as 3b, 3c and 10 in the drawings of Figs. 1b and 2a.
  • Figs. 1a to 1h provide a step-by-step depiction of a first embodiment of the process for assembling a thermally insulated battery module as described herein.
  • the battery module is shown cross-sectionally as having a rectangular cuboidal housing (1) with a top and a base. There are two pairs of opposite sides between the top and the base. The two pairs of opposite sides (not shown) between the top and the base, define an enclosure with one pair of the opposite sides having electrical mountings (again not shown) .
  • the electrical mountings are positioned so that multiple battery cells can be mounted horizontally between opposite electrical mountings on the opposite sides such that when mounted there are a plurality of cylindrical battery cells (4) in a horizontal array in said enclosure.
  • a base mat (2) preferably made from a suitable thermal insulation material such as a silicone elastomeric material, e.g., a silicone foam, is inserted onto the base of housing (1) .
  • a suitable thermal insulation material such as a silicone elastomeric material, e.g., a silicone foam
  • Fig. 1b depicts three prefabricated cured silicone foam parts, (3a, 3b and 3c) which are used in this first embodiment to thermally insulate battery cells (4) in housing (1) .
  • Prefabricated cured silicone foam part (3a) is a first plano-concave prefabricated cured silicone foam part.
  • Prefabricated cured silicone foam part (3b) is a biconcave prefabricated cured silicone foam part used between horizontally adjacent battery cells (4) .
  • Prefabricated cured silicone foam part (3c) is a second plano-concave prefabricated cured silicone foam part.
  • Multiple prefabricated cured silicone foam parts, (3a, 3b and 3c) are utilized in the process for assembling a thermally insulated battery module as described herein.
  • Fig. 1b depicts three prefabricated cured silicone foam parts, (3a, 3b and 3c) which are used in this first embodiment to thermally insulate battery cells (4) in housing (1) .
  • Prefabricated cured silicone foam part (3a) is a first plano-con
  • a first battery (4) is electrically mounted between corresponding opposite electrical mounts on a pair of opposite sides of the housing (1) .
  • a first prefabricated cured silicone foam part (3b) is fitted next to said first battery cell and then a second battery cell (4) is electrically mounted between its corresponding opposite electrical mounts on the pair of opposite sides of the housing (1) sandwiching the first prefabricated cured silicone foam part (3b) therebetween, filling the type (II) (a) void which would have otherwise been formed. This process is then repeated until each battery cell is correctly mounted.
  • two adjacent battery cells (4) can be electrically mounted and a prefabricated cured silicone foam part (3b) is inserted in the type (II) (a) void between the neighbouring battery cells (4) .
  • a prefabricated cured silicone foam part (3a) inserted between itself and the side of the enclosure of housing (1) (i.e., a type (II) (b) void between the last battery cell (4) in the row and the enclosure side within the housing enclosure) .
  • a fluid cooling manifold (5a) is shown inserted on top of the bottom row of battery cells (4) thermally insulated with prefabricated cured silicone foam parts (3a and 3b) .
  • Each fluid cooling manifold layer may comprise a single fluid cooling manifold, in this instance depicted as (5a) but the layer may alternatively comprise two or more horizontally adjacent fluid cooling manifolds (5a) (not depicted) .
  • Each fluid cooling manifold e.g., 5a
  • a middle layer of horizontal battery cells (4) has been introduced and sit on fluid cooling manifold (5a) .
  • the voids between horizontally adjacent battery cells (4) in said middle row have been filled with prefabricated cured silicone foam parts (3b) as described above but in this instance larger type (II) (b) voids occur between the last battery cell and the side of housing (1) enclosure and as such in this case a prefabricated cured silicone foam part (3c) has been inserted between itself and the side of the enclosure of housing (1) .
  • a second fluid cooling manifold (5b) has been inserted on top of the second layer of horizontal battery cells (4) .
  • a third layer of battery cells (4) have been added and horizontally neighbouring battery cells have voids (II) (a) therebetween filled with a prefabricated cured silicone foam parts (3b) as described above.
  • each end battery cell (4) with only a single horizontal neighbour has a prefabricated cured silicone foam part (3a) inserted between itself and the side of the enclosure of housing (1) (i.e., a void (II) (b) surrounding the battery module assembly within the housing enclosure.
  • a top layer (6) is added. Top layer (6) is equivalent to base layer (2) and completes the thermal insulation of the enclosure.
  • FIG. 2a A second embodiment of the process is depicted in Figs. 2a to 2h.
  • Fig. 2a there are provided cross-sections of the two alternative types of elongate prefabricated cured silicone foam parts (10) and (12) used in this second embodiment.
  • one or more fluid cooling manifold (s) (5) is/are encapsulated within each elongate prefabricated cured silicone foam part (12) .
  • a base mat (2) preferably made from a suitable thermal insulation material such as a silicone elastomeric material, e.g., a silicone foam, is inserted onto the base of housing (1) and a prefabricated cured silicone foam part (10) has been positioned on top of base mat (2) , ready to receive battery cells (4) .
  • a prefabricated cured silicone foam part (10) has been positioned on top of base mat (2) , ready to receive battery cells (4) .
  • several battery cells (4) have been electrically mounted between corresponding electrical mounts (not shown) on a pair of opposite sides of the housing (1) and sit in the concave spaces provided in prefabricated cured silicone foam part (10) .
  • a prefabricated cured silicone foam part (12a) has been placed on top of the battery cells (4) and prefabricated cured silicone foam part (10) thereby effectively encapsulating/surrounding the battery cells (4) .
  • Prefabricated cured silicone foam part (12a) is also designed to provide concave receiving means for the middle row of battery cells (4) .
  • the said second layer of battery cells (4) have been electrically mounted and sit in the concave receiving means of prefabricated cured silicone foam part (12a) .
  • a prefabricated cured silicone foam part (12b) is inserted over the second layer of battery cells (4) and effectively completing the encapsulation/surrounding the battery cells (4) in the middle horizontal row of battery cells (4) .
  • Prefabricated cured silicone foam part (12b) is also designed to provide concave receiving means for the top horizontal row of battery cells (4) .
  • battery cells (4) are seen inserted in the concave receiving means of prefabricated cured silicone foam part (12b) and Fig. 2h depicts a second prefabricated cured silicone foam part (10) depicted as (10b) placed over the top row of battery cells (4) and completing the thermal insulation of the enclosure of housing (1) .
  • a third embodiment depicted option (III) (b) in Figs. 3a to 3i the process depicted in Figs. 1a to 1h is repeated with the exception that plano-convex prefabricated cured silicone foam parts (3a) and (3c) are not utilized but are replaced by dispensing a curable silicone foam composition into the enclosure, to fill the type (II) (b) type voids surrounding the battery module assembly within the enclosure of housing (1) .
  • a silicone elastomeric material e.g., a silicone foam
  • a bottom row of battery cells (4) are electrically mounted in the enclosure of housing (1) .
  • Each battery cell (4) having two horizontal neighbours is separated from each neighbour using a prefabricated cured silicone foam part (3b) , but prefabricated cured silicone foam parts (3a) are not inserted to thermally insulate the type (II) (b) voids.
  • a first layer of fluid cooling manifold (s) (5x) is placed over the bottom row of thermally insulated battery cells (4) and then as depicted in Fig. 3d a middle row of battery cells (4) are electrically mounted in the enclosure of housing (1) .
  • Each battery cell (4) having two horizontal neighbours is separated from each horizontal neighbour using prefabricated cured silicone foam parts (3b) , but prefabricated cured silicone foam parts (3c) are not inserted.
  • a second layer of fluid cooling manifold (s) (5y) is placed over the middle row of thermally insulated battery cells (4) and then in Fig. 3f a top row of battery cells (4) are electrically mounted in the enclosure of housing (1) .
  • Each battery cell (4) having two horizontal neighbours is separated from each neighbour using prefabricated cured silicone foam parts (3b) , but prefabricated cured silicone foam parts (3a) are again not inserted.
  • a top mat (2) preferably made from a suitable thermal insulation material such as a silicone elastomeric material, e.g., a silicone foam is placed on to the top layer of insulated battery cells (4) .
  • a suitable thermal insulation material such as a silicone elastomeric material, e.g., a silicone foam
  • voids 20a and 20b are depicted in Fig. 3f, 3g and 3h because foam parts (3a and (3b) were not utilized.
  • dispensing tips (32) and (30) are inserted into voids 20a and 20b respectively. It was found that the dispensing tips were best positioned such the liquid foam encapsulant is introduced into voids (20a) and (20b) at a depth in the enclosure between base mat (2) and the first layer of fluid cooling manifold (s) (5x) .
  • Fig. 3i depicts a fully thermally insulated enclosure of housing (1) using this third embodiment. In such circumstances the curable silicone foam composition is then cured in (IV) .
  • FIG. 4 show molded parts the cross-sections of which are depicted as 3b, 3c and 10 in the drawings of Figs. 1b and 2a.
  • thermally insulated battery modules described herein are suitable for use in a wide variety of applications such as in electric-vehicle battery (EVB) power supplies for electric and hybrid (electric and petrol/diesel) powered vehicles, i.e., in battery packs/systems used to power the propulsion system of electric and hybrid vehicles and as such are designed to give power over sustained periods of time.
  • the thermally insulated battery module is used in a battery pack in a vehicle such as an all-electric road vehicle (EV) , a plug-in hybrid road vehicle (PHEV) , a hybrid road vehicle (HEV) or alternatively in other modes of transport such as an aircraft, a boat, a ship, a train.
  • a vehicle such as an all-electric road vehicle (EV) , a plug-in hybrid road vehicle (PHEV) , a hybrid road vehicle (HEV) or alternatively in other modes of transport such as an aircraft, a boat, a ship, a train.
  • EV all-electric road vehicle
  • PHEV plug-in
  • Polymer 1 dimethylvinyl terminated polydimethylsiloxane having a viscosity of 350 mPa. s at 25°C;
  • Hydromagnesite a hydrated magnesium carbonate mineral having the formula
  • Mg 5 (CO 3 ) 4 (OH) 2 ⁇ 4H 2 O having an average particle size of about 4 ⁇ m, hydrophobically treated with a vinyl silazane;
  • Glass Bubbles the glass bubbles used in the comparative Example 1 (C. 1) were commercially available from the 3M Corporation as 3M TM Glass Bubbles S32HS;
  • Resin foam stabilizer a Vi MMQ resin, having a viscosity of ⁇ 45,000 mPa. s at 25°C and ⁇ 0.39 wt. %vinyl;
  • Karstedt s catalyst: a masterbatch of dimethylvinylsiloxy-terminated dimethyl siloxane and platinum complex. Platinum complex content is about 1.4%;
  • Fluorinated silicone polymer a trimethyl terminated polydimethyl methyl perfluoropropyl siloxane having a viscosity of about 10,000 mPa. s at 25°C;
  • Fluorinated silicone resin (viscosity ⁇ 100 mPa. s at 25°C)
  • Organohydrogensiloxane methylhydrogen siloxane, trimethylsiloxy-terminated, having a viscosity of about 20 mPa. s at 25°C and about 1.6 wt. %SiH.
  • Table 1a Part A and Part B compositions of Examples 1 & 2 and Comparative 1 (wt. %)
  • the part A composition was prepared in an analogous fashion in each example/comparative, wherein the ingredients excepting the blowing agent were weighed into a Turello mixer container. They were then mixed using a Turello mixer (600 rpm, 20 min) . to form a homogeneous mixture. The mixture was then cooled to 5 °C, and the blowing agent was introduced forming a homogeneous mixture.
  • part B composition was prepared in an analogous fashion in each example/comparative, all the ingredients were weighed into a Turello mixer container. They were then mixed using said Turello mixer (600 rpm, 20 min) to produce a homogeneous mixture If it is needed to add foam blowing agent, follow the same procedure as described in part A.
  • the thermal testing was undertaken on a test station comprising a heatable base plate with heat face dimension of 15cm x 17cm to provide heating temperature at about 600°C, an aluminum plate with dimension of 15cm x 17cm x 3cm, and a steel loading plate.
  • the total weight of aluminum plate and steel loading plate was 19.2kg.
  • Test specimens were prepared having the dimensions 8cm length, 4cm width and approximately 2mm thickness. The test specimen was mounted on the center of the aluminum plate, facing to heatable base plate with the surface area directly contacting with the heatable base plate was 0.0064m 2 .
  • the steel loading plate was placed on the aluminum plate to make 0.03MPa pressure on the test specimen during testing.
  • Two line notches in parallel, with depth as 0.45mm were cut on the specimen holding face of aluminum plate, starting from the long edge (17cm) , end with length of 7.5cm, distance between the two line notches was 4cm, evenly positioned near the center of aluminum plate.
  • Two K-type jacketed thermocouples with O.D. as 0.5mm were placed in the lined notches to measure the back temperature of test specimen. Polyimide tape was used to fix thermocouples and mount test specimen on aluminum plate.
  • the test lasted for 20min, with back temperature of specimen recorded. After the test, steel loading and Aluminum plate was removed from the heat stage.
  • the temperature of the back face was ⁇ 250°C after 20 mins.
  • each of Ex. 1 & 2 showed excellent flowability and were able to self-level much better.
  • the viscosities of Ex. 1& 2 are all much lower i.e., between 800 and 1100 mPa. s at 25°C, which make the self-levelling easier to realize.
  • the thermal insulation performance and flame retardancy are also significantly enhanced.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Battery Mounting, Suspending (AREA)

Abstract

La présente invention concerne un procédé d'assemblage d'un module de batterie thermiquement isolé dans l'enceinte d'un boîtier de module de batterie conçu pour recevoir un ou plusieurs réseaux d'éléments de batterie cylindriques montés horizontalement (4). Lorsque les éléments de batterie cylindriques (4) sont montés dans les vides d'enceinte, sont créés entre des éléments de batterie cylindriques adjacents (4) et également entre l'ensemble module de batterie résultant et les côtés de l'enceinte. Des parties de mousse de silicone durcie préfabriquées (3b) sont utilisées pour remplir des vides formés entre des éléments de batterie cylindriques adjacents (4) et des parties de mousse de silicone durcies préfabriquées (3a, 3c) et/ou une composition de mousse de silicone durcissable est/sont utilisées (s) pour remplir les vides entre l'ensemble module de batterie résultant et les côtés de l'enceinte.
PCT/CN2021/141954 2021-12-28 2021-12-28 Assemblage de module de batterie WO2023122936A1 (fr)

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Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3419593A (en) 1965-05-17 1968-12-31 Dow Corning Catalysts for the reaction of = sih with organic compounds containing aliphatic unsaturation
US3445420A (en) 1966-06-23 1969-05-20 Dow Corning Acetylenic inhibited platinum catalyzed organopolysiloxane composition
US3715334A (en) 1970-11-27 1973-02-06 Gen Electric Platinum-vinylsiloxanes
US3814730A (en) 1970-08-06 1974-06-04 Gen Electric Platinum complexes of unsaturated siloxanes and platinum containing organopolysiloxanes
US3989667A (en) 1974-12-02 1976-11-02 Dow Corning Corporation Olefinic siloxanes as platinum inhibitors
US4550125A (en) 1985-03-25 1985-10-29 Dow Corning Corporation Foamable polyorganosiloxane compositions
US6476080B2 (en) 2000-12-21 2002-11-05 The Dow Chemical Company Blowing agent compositions containing hydrofluorocarbons and a low-boiling alcohol and/or low-boiling carbonyl compound
US6605734B2 (en) 2001-12-07 2003-08-12 Dow Corning Corporation Alkene-platinum-silyl complexes
US20140024731A1 (en) 2010-09-06 2014-01-23 Bluestar Silicones France Sas Silicone composition for elastomer foam
WO2018150279A1 (fr) * 2017-02-20 2018-08-23 Tesla, Inc. Bloc de stockage d'énergie
WO2020028299A1 (fr) * 2018-07-31 2020-02-06 Dow Silicones Corporation Composition, mousse d'élastomère de silicone formée à partir de celle-ci et procédés de formation correspondants

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3419593A (en) 1965-05-17 1968-12-31 Dow Corning Catalysts for the reaction of = sih with organic compounds containing aliphatic unsaturation
US3445420A (en) 1966-06-23 1969-05-20 Dow Corning Acetylenic inhibited platinum catalyzed organopolysiloxane composition
US3814730A (en) 1970-08-06 1974-06-04 Gen Electric Platinum complexes of unsaturated siloxanes and platinum containing organopolysiloxanes
US3715334A (en) 1970-11-27 1973-02-06 Gen Electric Platinum-vinylsiloxanes
US3989667A (en) 1974-12-02 1976-11-02 Dow Corning Corporation Olefinic siloxanes as platinum inhibitors
US4550125A (en) 1985-03-25 1985-10-29 Dow Corning Corporation Foamable polyorganosiloxane compositions
US6476080B2 (en) 2000-12-21 2002-11-05 The Dow Chemical Company Blowing agent compositions containing hydrofluorocarbons and a low-boiling alcohol and/or low-boiling carbonyl compound
US6605734B2 (en) 2001-12-07 2003-08-12 Dow Corning Corporation Alkene-platinum-silyl complexes
US20140024731A1 (en) 2010-09-06 2014-01-23 Bluestar Silicones France Sas Silicone composition for elastomer foam
WO2018150279A1 (fr) * 2017-02-20 2018-08-23 Tesla, Inc. Bloc de stockage d'énergie
WO2020028299A1 (fr) * 2018-07-31 2020-02-06 Dow Silicones Corporation Composition, mousse d'élastomère de silicone formée à partir de celle-ci et procédés de formation correspondants

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