WO2023134602A1 - Stratifié utile en tant qu'isolation de batterie d'élément à élément - Google Patents

Stratifié utile en tant qu'isolation de batterie d'élément à élément Download PDF

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Publication number
WO2023134602A1
WO2023134602A1 PCT/CN2023/071174 CN2023071174W WO2023134602A1 WO 2023134602 A1 WO2023134602 A1 WO 2023134602A1 CN 2023071174 W CN2023071174 W CN 2023071174W WO 2023134602 A1 WO2023134602 A1 WO 2023134602A1
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Prior art keywords
aerogel
laminate
outer layer
aramid
adhesive
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PCT/CN2023/071174
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English (en)
Inventor
Qi SHAO
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Dupont (China) Research & Development And Management Co., Ltd.
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Publication of WO2023134602A1 publication Critical patent/WO2023134602A1/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
    • H01M10/60—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
    • A—HUMAN NECESSITIES
    • A62—LIFE-SAVING; FIRE-FIGHTING
    • A62C—FIRE-FIGHTING
    • A62C3/00—Fire prevention, containment or extinguishing specially adapted for particular objects or places
    • A62C3/16—Fire prevention, containment or extinguishing specially adapted for particular objects or places in electrical installations, e.g. cableways
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B32B27/281—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyimides
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
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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
    • 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
    • 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
    • H01M50/242—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 against vibrations, collision impact or swelling
    • 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
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409—Separators, membranes or diaphragms characterised by the material
    • H01M50/44—Fibrous material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B32B2255/102—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer synthetic resin or rubber layer being a foamed layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B2255/00—Coating on the layer surface
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B2457/00—Electrical equipment
    • B32B2457/04—Insulators
    • 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

  • the present invention relates to a laminate useful as cell-to-cell battery insulation.
  • Multi-cell battery structures have battery cells positioned either in parallel or in series, and are commonly known as battery modules or battery packs.
  • the heat energy from unusual thermal issues, such as faults or failures in one cell can propagate to an adjacent cell. If the thermal issues are severe enough, they can propagate from one cell to an adjacent cell, and thus cause a runaway thermal condition that can cascade to all the cells in the battery module or battery pack, resulting in fire or even worse consequences.
  • Some proposed insulative materials have attributes that are undesirable to the manufacturers of batteries. Some insulative materials made from inorganic fibers have a high propensity to shed inorganic particles, which is undesirable in that they create dust and adhesion problems.
  • the present invention relates to a laminate useful as cell-to-cell battery insulation, the laminate having a central insulating area and a periphery seal area,
  • the central insulating area comprising, in order:
  • the periphery seal area being void of the inner layer and being formed by adhering the first and second outer layers to one another;
  • periphery seal area extends around the periphery of the central insulating area
  • first outer layer and the second outer layer independently of each other comprise at least one material selected from the group consisting of aramid material, a combination of aramid material and mica, polyethylene terephthalate and polyimide.
  • both the first outer layer and the second outer layer have flame-retardant property
  • the inner layer has good thermal insulation property and cushioning property by comprising an aerogel.
  • Figure 1 illustrates one type of laminate having a central insulating area and a peripheral seal area, not drawn to scale.
  • Figure 2 illustrates a cross section A-A’ of the laminate of Figure 1 showing a part of the central insulating area and the periphery seal area and individual layers in these areas, not drawn to scale.
  • Figure 3 illustrates a curve of temperature versus time of a laminate according to the present invention under conditions simulating thermal runaway.
  • Figure 4 illustrates a curve of thickness versus time of a laminate according to the present invention under conditions simulating thermal runaway.
  • Figure 5 illustrates a curve of temperature versus time of a laminate according to the present invention under conditions simulating thermal runaway.
  • Figure 6 illustrates a curve of thickness versus time of a laminate according to the present invention under conditions simulating thermal runaway.
  • Figure 7 illustrates a curve of temperature versus time of a comparative laminate under conditions simulating thermal runaway.
  • Figure 8 illustrates a curve of thickness versus time of a comparative laminate under conditions simulating thermal runaway.
  • the present invention relates to a laminate useful as cell-to-cell battery insulation, the laminate having a central insulating area and a periphery seal area,
  • the central insulating area comprising, in order:
  • the periphery seal area being void of the inner layer and being formed by adhering the first and second outer layers to one another;
  • periphery seal area extends around the periphery of the central insulating area
  • first outer layer and the second outer layer independently of each other comprise at least one material selected from the group consisting of aramid material, a combination of aramid material and mica, polyethylene terephthalate and polyimide.
  • the first outer layer and the second outer layer may be identical with or different from each other, preferably identical with each other.
  • the aerogel may be in the form of felt, paper or blanket.
  • cell-to-cell insulation it is meant materials that are inserted between individual battery cells in a multi-cell battery structure that provide thermal insulation; that is, they attempt to thermally isolate each battery cell and also retard the transfer of heat energy should the battery cell develop a thermal “hot spot” or have an unusual thermal issue such as a thermal runaway, which could result in an explosion.
  • Figure 1 illustrates one version of the laminate 1 having a central insulating area (hereinafter referred as "insulating area” ) 2 extending in the plane of the laminate to the periphery seal area 3; and the periphery seal area 3 extends around the entire central insulating area 2.
  • the central insulating area 2 provides the bulk of the insulation and elasticity for the laminate 1, while the periphery seal area 3 extends around the periphery of the central insulating area 2 and effectively seals the edges of the central insulating area 2, encapsulating the materials of the inner layer inside the laminate 1.
  • one optional feature shown in Figure 1 is one possible arrangement of two pieces of double-sided tapes 4 that are attached to the surface of the central insulating area 2.
  • the double-sided tape 4 can be used to adhere the laminate 1 to the battery cell or to position the laminate 1 in the battery module or pack. Double-sided tapes comprising a flame-retardant adhesive are preferred.
  • the area of the double-sided tape 4 can be as large as covering the whole insulating area 2, or the double-sided tape can be one or more pieces of tapes as needed.
  • the double-sided tape 4 can be replaced with conventional adhesives.
  • adhesives There is no particular limitation on the type of adhesives, and either an adhesive that is liquid at room temperature (about 25°C) or a hot-melt adhesive that is solid at room temperature can be used in the present invention.
  • the adhesive is preferably a flame-retardant adhesive.
  • the central insulating area comprises, in order, a first outer layer comprising at least one material selected from the group consisting of aramid material, a combination of aramid material and mica, polyethylene terephthalate and polyimide; an inner layer comprising an aerogel, preferably a fiber-reinforced aerogel, more preferably a fiber-reinforced silica aerogel; and a second outer layer comprising at least one material selected from the group consisting of aramid material, a combination of aramid material and mica, polyethylene terephthalate and polyimide.
  • one face of the inner layer is directly bound to a face of the first outer layer and the opposing face of the inner layer is directly bound to a face of the second outer layer.
  • FIG. 2 is the cross-sectional view along the A-A’ line from Figure 1.
  • the dotted curve in Figure 2 represents where the A-A’ cut line in Figure 1 lies.
  • the inner layer 11 comprises an aerogel, preferably a fiber-reinforced aerogel, more preferably a fiber-reinforced silica aerogel.
  • the inner layer 11 is sandwiched between the first outer layer 10 and the second outer layer 12, forming the central insulating area.
  • the first outer layer 10 and the second outer layer 12 extend beyond the outer edge or periphery of the inner layer 11 and are adhered to each other.
  • the first and second outer layers are bound to the inner layer by use of a suitable adhesive to form the central insulating area, and the first and second outer layers are also adhered to each other by a suitable adhesive, preferably the same adhesive as mentioned above to form the periphery seal area.
  • the periphery seal area has a width 14.
  • the periphery seal area is continuous around the periphery of the central insulating area, and preferably the width of the periphery seal area is constant around the entire periphery of the central insulating area; that is, the periphery seal area has an equal width on all sides.
  • the periphery seal area is void of the inner layer; that is, the inner layer is not present in the periphery seal area.
  • the periphery seal area should be wide enough to adequately seal-in the materials of the inner layer in the laminate to block the shedding of the inorganic matter in the inner layer. As shown in Figure 2, the width 14 extending from the outer edge of the laminate to the edge of the inner layer should also be adequate for the laminate to withstand handling during battery module or pack manufacture and subsequent use without the periphery seal being ruptured. In some embodiments, the periphery seal area extending around the entire central insulating area has a width of 2 to 15 mm. In some embodiments, the periphery seal area extending around the entire central insulating area has a width of 2 to 10 mm.
  • the first outer layer comprises at least one material selected from the group consisting of aramid material, a combination of aramid material and mica, polyethylene terephthalate and polyimide.
  • the aramid material, or the combination of aramid material and mica is in the form of paper, floc, fibrid, or mixtures thereof.
  • the polyethylene terephthalate or the polyimide is in the form of film.
  • the first outer layer comprises 50 to 70 %by weight of uniformly distributed mica and 30 to 50 %by weight of aramid material, based on the total weight of the first outer layer.
  • the first outer layer comprises 50 to 60 %by weight of uniformly distributed mica and 40 to 50 %by weight of aramid material, based on the total weight of the first outer layer.
  • the second outer layer comprises at least one material selected from the group consisting of aramid material, a combination of aramid material and mica, polyethylene terephthalate and polyimide.
  • the aramid material, or the combination of aramid material and mica is in the form of paper, floc, fibrid, or mixtures thereof.
  • the polyethylene terephthalate or polyimide is in the form of film.
  • the second outer layer comprises 50 to 70 %by weight of uniformly distributed mica and 30 to 50 %by weight of aramid material, based on the total weight of the second outer layer.
  • the second outer layer comprises 50 to 60 %by weight of uniformly distributed mica and 40 to 50%by weight of aramid material, based on the total weight of the second outer layer.
  • the aramid material, the combination of aramid material and mica, the polyethylene terephthalate, and/or the polyimide in the first and second out layers provide flame retardancy, fire retardancy, and resistance to high temperature.
  • both the first and second outer layers are layers of paper. It is believed that at least about 50 %by weight of mica is preferred in both the first and second outer layers so as to provide desirable dimensional stability of those layers under flame conditions, as evidenced by minimal crack formation, shrinkage, and swelling of the first and second outer paper layers under flame. Also, while in the outer layers, amounts of mica greater than 70 %by weight are useful from a fire-blocking and dimensional stability standpoint. However, it is believed that as the amount of mica in the outer layers increases above 70 %by weight the outer layers have more propensity to shed the mica, therefore in some applications, amounts of mica greater than 70 %by weight would be undesirable.
  • uniformly-distributed mica it is meant that the mica can be homogenously distributed throughout the thickness of the outer layer, or that the mica can be uniformly and areally distributed throughout a concentrated planar zone in the outer layer that is closer to one of the faces of the layer. Implicit in this definition is that the mica is sufficiently distributed so as to provide the desired performance of the final laminate structure.
  • the mica can include muscovite or phlogopite mica, or blends thereof, and may be calcined or uncalcined mica.
  • Calcined mica as used herein means mica that is obtained by heating natural mica to a high temperature (usually greater than 800°C, sometimes greater than 950°C) . This treatment removes water and impurities and improves the temperature resistance of the mica. Calcined mica is normally used in the form of a flake particle and mica of the muscovite type is preferred.
  • Uncalcined mica as used herein means mica that is essentially in pure natural form that has preferably been homogenized and purified to remove imperfections and impurities.
  • Uncalcined mica can form a very porous mica layer due to the larger size of the natural mica flakes.
  • the preferred mica used in the first outer layer and/or the second outer layer is calcined mica, due to its improved dielectric properties and corona resistance over uncalcined mica.
  • the first and second outer layers can independently have a preferred thickness of from 0.01 to 0.25 mm and a basis weight of from 10 to 300 grams per square meter. In some embodiments, the first and second outer layers can independently have a thickness of from 0.03 to 0.1 mm. In some embodiments, the first and second outer layers can independently have a basis weight of from 45 to 120 grams per square meter. In some most preferred embodiments, the first and second outer layers have the same thickness and basis weight.
  • Aerogels are a class of porous materials comprising open pores with framework having an interconnected structure, wherein the corresponding network of pores is integrated in the framework, the network of the pores have an interstitial phase, and the interstitial phase mainly comprises a gas, such as air. Aerogels are characterized by low density, high porosity, large surface area, and small pore size. Therefore, aerogels can provide good thermal insulation and cushioning properties.
  • the aerogel may have one or more of the following physical properties and structural properties (according to the nitrogen porosimetry test) : (a) an average pore diameter of from about 2 nm to about 100 nm, (b) a porosity of at least 80%or more, and (c) a surface area of about 20 m 2 /g or more.
  • the aerogel may also have one or more of the following physical properties: (d) a pore volume of about 2.0 mL/g or more, preferably about 3.0 mL/g or more; (e) a density of about 0.50 g/cc or less, preferably about 0.25 g/cc or less; and (f) at least 50%of the pore volume involves pores with a pore diameter of 2 to 50 nm.
  • the aerogel is selected from the group consisting of inorganic aerogels, organic aerogels and organic-inorganic hybrid aerogels.
  • the inorganic aerogel may be based on oxides, carbides and/or nitrides of silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium and cerium, preferably the inorganic aerogel is a silica aerogel.
  • the organic aerogel may be based on at least one of the following organic polymers: polyamides, polyimides, poly (meth) acrylic acids, poly (meth) acrylates, polyacrylamides, polyacrylonitriles, polystyrenes, polyurethanes, polybutadienes, polyfurfuryl alcohols, polyisocyanates, epoxy resins, polysiloxanes, polyglucosamines, polyethers, chitosans and polybenzimidazoles.
  • organic polymers polyamides, polyimides, poly (meth) acrylic acids, poly (meth) acrylates, polyacrylamides, polyacrylonitriles, polystyrenes, polyurethanes, polybutadienes, polyfurfuryl alcohols, polyisocyanates, epoxy resins, polysiloxanes, polyglucosamines, polyethers, chitosans and polybenzimidazoles.
  • the organic-inorganic hybrid aerogel may be based on any combination of an inorganic substance and an organic polymer, wherein said inorganic substance is selected from the group consisting of oxides, carbides and/or nitrides of silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium and cerium, and the organic polymer is selected from the group consisting of polyamides, polyimides, poly (meth) acrylic acids, poly (meth) acrylates, polyacrylamides, polyacrylonitriles, polystyrenes, polyurethanes, polybutadienes, polyfurfuryl alcohols, polyisocyanates, epoxy resins, polysiloxanes, polyglucosamines, polyethers, chitosans and polybenzimidazoles.
  • said inorganic substance is selected from the group consisting of oxides, carbides and/or nitrides of silicon, aluminum, titanium, zirconium, hafnium, yttrium
  • the organic-inorganic hybrid aerogel is selected from the group consisting of silica-polysiloxanes, silica-polyethers, silica-poly (meth) acrylates and silica-chitosans.
  • the aerogel is a fiber-reinforced aerogel.
  • Fiber-reinforced aerogels can improve the mechanical properties of the aerogels, for example, flexibility, resilience, uniformity and/or structural stability.
  • the fibers may be selected from the groups consisting of glass fibers, ceramic fibers, polyacrylonitrile (PAN) fibers and oxidized polyacrylonitrile fibers.
  • the glass fiber may be selected from S-glass, 901 glass, 902 glass, 475 glass, E-glass and the like.
  • the fiber-reinforced aerogel comprises an aerogel attached to fibers.
  • the inner layer may be in the form of felt, paper or blanket comprising aerogel.
  • the felt, paper or blanket of silica aerogel used in the inner layer further comprises an organic or inorganic adhesive, and one useful and exemplary organic adhesive is an acrylic adhesive.
  • the felt, paper or blanket comprising the aerogel may have a thickness of from 0.3 to 10 mm and a basis weight of from 40 to 2200 grams per square meter. In some embodiments, the aerogel layer may have a thickness of from 0.5 to 8 mm. In some embodiments, the felt, paper or blanket comprising the aerogel may have a basis weight of from 70 to 1500 grams per square meter.
  • the central insulating area and the periphery seal area of the laminate have different thickness, with the central insulating area being thicker due to the presence of the inner layer, and the periphery seal area being thinner due to the absence of the inner layer.
  • the central insulating area of the laminate has a thickness of from about 0.35 mm to 7 mm. In some preferred embodiments, the central insulating area of the laminate has a thickness of from about 0.85 to 6 mm.
  • the periphery seal area of the laminate has a thickness of from about 0.04 to 0.60 mm. In some preferred embodiments, the periphery seal area of the laminate has a thickness of from about 0.06 to 0.25 mm.
  • the laminate has a total basis weight of from about 300 to 1600 grams per square meter, for example, from about 800 to 1200 grams per square meter. If the central insulating area and the periphery seal area of the laminate were separated, one would find that the insulating area accounts for most of this basis weight; and by itself would have a basis weight of about 240 to 1500 grams per square meter. Likewise, the narrow periphery seal by itself would have a basis weight of only about 2 to 100 grams per square meter.
  • aramid floc means aramid fibers having a short length and that are customarily used in the preparation of wet-laid sheets and/or papers. Typically, aramid floc has a length of from about 3 to about 20 millimeters. A preferred length of aramid floc is from about 3 to about 7 millimeters. Aramid floc is normally produced by cutting continuous fibers into the required lengths using well-known methods in the art.
  • aramid means aromatic polyamide, wherein at least 85%of the amide (-CONH-) linkages are attached directly to two aromatic rings.
  • additives can be used with the aramid and may be dispersed throughout the polymer structure. It has been found that up to as much as about 10 percent by weight of other supporting material can be blended with the aramid. It has also been found that copolymers can be used having as much as about 10 percent of other diamines substituted for the diamine of the aramid or as much as about 10 percent of other diacid chlorides substituted for the diacid chloride of the aramid.
  • the preferred aramid is a meta-aramid.
  • the aramid polymer is considered a meta-aramid when the two rings or radicals are meta oriented with respect to each other along the molecular chain.
  • the preferred meta-aramid is poly (meta-phenylene isophthalamide) (MPD-l) .
  • MPD-l poly (meta-phenylene isophthalamide)
  • U.S. Patent Nos. 3,063,966; 3,227,793; 3,287,324; 3,414,645; and 5,667,743 are illustrative of useful methods for making aramid fibers that could be used to make aramid floc.
  • the aramid floc could be a para-aramid or an aramid copolymer.
  • the aramid polymer is considered a para-aramid when the two rings or radicals are para oriented with respect to each other along the molecular chain.
  • Methods for making para-aramid fibers are generally disclosed in, for example, US Patent Nos. 3,869,430; 3,869,429; and 3,767,756.
  • One preferred para-aramid is poly (paraphenylene terephthalamide) ; and one preferred para-aramid copolymer is copoly (p-phenylene/3, 4’-diphenyl ester terephthalamide) .
  • the preferred aramid floc is a meta-aramid floc, and especially preferred is floc made from the meta-aramid poly (meta-phenylene isophthalamide) (MPD-l) .
  • fibrouss means very small, nongranular, fibrous or film-like particles with at least one of their three dimensions being of minor magnitude relative to the largest dimension. These particles are prepared by precipitation of a solution of supporting material using a non-solvent under high shear, as disclosed for example in U.S. Patent Nos. 2,988,782 and 2,999,788.
  • Aramid fibrids are non-granular film-like particles of aromatic polyamide having a melting point or decomposition point above 320°C.
  • the preferred aramid fibrid is a meta-aramid fibrid, and especially preferred are fibrids made from the meta-aramid poly (meta-phenylene isophthalamide) (MPD-I) .
  • Fibrids generally have a largest dimension length in the range of from about 0.1 mm to about 1 mm with a length-to-width aspect ratio of from about 5: 1 to about 10: 1.
  • the thickness dimension is on the order of a fraction of a micron, for example, from about 0.1 microns to about 1.0 micron.
  • aramid fibrids While not required, it is preferred to incorporate aramid fibrids into the layers while the fibrids are in a never-dried state.
  • the first and second outer layers comprise the aramid material being in the form of floc, fibrid, or mixtures thereof. When a mixture of floc and fibrids is used for the aramid, a preferred calculated weight ratio of floc to fibrid is in a range of from 0.5 to 4.0 and more preferably from 0.8 to 2.0.
  • the term "layer” as used in the first outer layer, the second outer layer and the inner layer, preferably refers to a thin planar material of a specific composition.
  • the term “layer” also refers to a paper made from a plurality of thin planar webs attached together wherein all the planar webs have the same composition.
  • the first outer layer is preferably the first outer layer of paper; and the second outer layer is preferably the second outer layer of paper.
  • face/surface refers to either of the two major surfaces of both the first and second outer layers, or either of the two major surfaces of the inner layer (i.e., one side or the other of the outer layer or the inner layer) .
  • the first and second outer layers can be directly bound to the inner layer in the insulating area by use of a continuous or discontinuous layer of adhesive; while the first and second outer layers can be directly bound to each other in the periphery seal area by preferential use of a continuous layer of adhesive.
  • each of the layers are made separately and then combined with a layer of adhesive provided in between, with the layers being, in order, the first outer layer, the inner layer, and then the second outer layer.
  • Each of the first and second outer layers can be made separately on a paper-making machine by providing an aqueous dispersion for the first outer layer or the second outer layer of the desired amount and composition to the headbox, and then wet-laying the composition as a web onto a papermaking wire.
  • the wet web can then be dried on dryer drums to form a paper.
  • the paper is then further calendered in the nip of a hot roll calender under pressure and heat, or by other means, to consolidate and densify the paper into a paper layer having the desired thickness.
  • two or more lighter basis weight or thinner wet webs or papers of the same composition can be made separately and then calendered and consolidated together into a single paper layer to form each of the first and second outer layers.
  • each of the first and second outer layers is calendered separately prior to being combined with the inner layer in the laminate structure.
  • PET films such as a Mylar sheet commercially available from Dupont, can be prepared via transesterification and vacuum polycondensation by heating dimethyl terephthalate and ethylene glycol with the aid of relevant catalysts; and biaxial stretching.
  • Polyimide (PI) films can be prepared by low temperature solution polycondensation of dianhydride and diamine in a polar solvent (such as dimethylformamide, dimethylacetamide, etc. ) to synthesize polyamic acid, followed by dehydration at high temperature to cyclize into the imide.
  • a polar solvent such as dimethylformamide, dimethylacetamide, etc.
  • Kapton film commercially available from Dupont, can be prepared by thermal cyclization of imine or cyclization of imine using pyromellitic dianhydride monomer as a raw material.
  • a liquid adhesive is applied to at least one face of a layer in a relatively uniform manner.
  • the adhesive can be applied to either a paper layer or film (i.e., the inner layer) using any method that provides a uniform application of adhesive to one side of the layer; and such methods include, but not limited to, those that involve roll coating or blade coating or spray coating, and not limited to theses only.
  • the adhesive is applied to a uniform thickness, and the adhesive is continuous in the laminate structure.
  • One method of making the laminate is to cut the first and second outer layers to the desired size dimensions (length and width, radius, etc. ) and shape (rectangular, circular, etc. ) , preferably the same size and shape.
  • the inner layer is then cut to its desired size and shape. Generally, this is the same shape but having smaller size such that when the laminate is formed, a periphery seal area can be formed that extends around the entire periphery of the central insulating area (the area containing the inner layer) .
  • the layers and adhesive are preferably then pressed together, with the adhesive positioned in between the layers, using any method that can press or consolidate the layers together to form the desired structure having no inner layer exposed at the edge of the laminate.
  • pressing methods could include nipping the layers (with adhesive between) in the nip (s) of a set of embossed calender rolls. This consolidates the layers into a laminate structure having the desired thickness and fully and directly binds the layers together.
  • the final laminate has an insulating area consisting of three layers plus the adhesive positioned between the layers; the inner layer having a first surface and a second surface, the first surface adhered with an adhesive to the first outer layer and the second surface adhered with an adhesive to the second outer layer.
  • the final laminate further has a periphery seal consisting of the first and second outer layers adhered to each other with an adhesive.
  • Laminate 1 was made having first and second outer layers of Type 864 (T864) paper, available from E. I. du Pont de Nemours and Co., Wilmington, Delaware (DuPont) , and an inner layer of fiber-reinforced silica aerogel felt.
  • T864 paper is an aramid paper containing about 50 %by weight of mica and about 50 %by weight of aramid materials, the aramid materials comprising about 25 %by weight of floc and about 75 %by weight of fibrids.
  • T864 paper is a consolidated (calendered) paper having a thickness of about 3 mils (0.076 mm) and a basis weight of about 90 grams per square meter.
  • the fiber-reinforced silica aerogel felt is composed of glass fibers and a silica aerogel, and has a measured thickness of about 4.83 mm and a basis weight of about 1000 grams per square meter.
  • the 3 mil T864 paper was cut into two identical square pieces (100 x 100 mm) .
  • the fiber-reinforced silica aerogel felt was also cut into a square piece, but both the length and width dimensions of the fiber-reinforced silica aerogel felt square were 20 mm shorter than the T864 paper squares.
  • the fiber-reinforced silica aerogel felt was then sandwiched between the two T864 paper and laminated using a polyurethane adhesive to adhere the layers together. Care was taken that the fiber-reinforced silica aerogel felt was centered on the T864 paper; its smaller dimensions leaving a 10-mm area extending around the laminate where the two T864 paper squares were attached to one another.
  • the width of the periphery seal area was 10 mm on all four sides of the square laminate 1.
  • the resulting laminate 1 had a central insulating area of T864 paper /SiO 2 aerogel T864 paper and a periphery seal area of T864 T864 paper.
  • the resulting laminate 1 provided a sealed structure with limited shedding potential.
  • Laminate 2 was prepared in the same manner as that in Example 1, except that the fiber-reinforced silica aerogel as the inner layer had a thickness of about 5.74 mm and a basis weight of about 1210 grams per square meter.
  • the resulting laminate 2 had a central insulating area of T864 paper/SiO 2 aerogel T864 paper and a peripheral seal area of T864 T864 paper.
  • the resulting laminate 2 provided a sealed structure with limited shedding potential.
  • Laminate 3 was prepared in the same manner as that in Example 1, except that the fiber-reinforced silica aerogel as the inner layer was replaced with ceramic fiber paper.
  • the ceramic fiber paper had a thickness of 9 mm and a basis weight of 1890 grams per square meter.
  • the resulting laminate 3 had a central insulating area of T864 paper/ceramic fiber T864 paper and a peripheral seal area of T864 T864 paper.
  • the resulting laminate 3 provided a sealed structure with limited shedding potential.
  • Laminate 1 prepared in Example 1 was placed on a hot plate equipped with a motor for applying a pressure. The switches of both the hot plate and the motor were turned on. The temperature of the hot plate was increased to a peak temperature of 600°Cwithin 1 minute. Then, the peak temperature of 600°C was maintained for about 11 minutes. Also, the pressure of the motor was increased to 0.2 MPa within the first 2 minutes. Then, the pressure of 0.2 MPa was maintained for about 10 minutes.
  • Laminate 2 prepared in Example 2 was placed on a hot plate equipped with a motor for applying a pressure. The switches of both the hot plate and the motor were turned on. The temperature of the hot plate was increased to a peak temperature of 800°Cwithin 2 minutes. Then, the peak temperature of 800°C was maintained for about 10 minutes. Also, the pressure of the motor was increased to 0.5 MPa within the first 2 minutes. Then, the pressure of 0.5 MPa was maintained for about 10 minutes.
  • Laminate 3 prepared in Comparative Example 1 was placed on a hot plate equipped with a motor for applying a pressure. The switches of both the hot plate and the motor were turned on. The temperature of the hot plate was increased to a peak temperature of 600°C within 1 minute. Then, the peak temperature of 600°C was maintained for about 11 minutes. Also, the pressure of the motor was increased to 0.2 MPa within the first 2 minutes. Then, the pressure of 0.2 MPa was maintained for about 10 minutes.
  • Test Examples 1 to 2 and Comparative Test Example 1 the temperature of the surface of the hot plate was measured with thermocouple (s) as the temperature of the hot plate, and the temperatures of the sides of Laminates 1 to 3 away from the hot plate was measured as the temperature of the back plate.
  • the curves of temperature versus time were drawn in Figure 3, 5 and 7, respectively.

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Abstract

Un stratifié utile en tant qu'isolation de batterie d'élément à élément, le stratifié ayant une zone isolante centrale et une zone d'étanchéité périphérique, la zone isolante centrale comprenant, dans l'ordre : 1) une première couche externe ; 2) une couche interne comprenant un aérogel ; et 3) une seconde couche externe ; la zone d'étanchéité périphérique étant dépourvue de la couche interne et étant formée en faisant adhérer les première et seconde couches externes l'une à l'autre, la zone d'étanchéité périphérique s'étendant autour de la périphérie de la zone isolante centrale ; et la première couche externe et la seconde couche externe comprenant indépendamment l'une de l'autre au moins un matériau choisi dans le groupe constitué par les matériaux d'aramide, une combinaison de matériau d'aramide et de mica, de polyéthylène téréphtalate et de polyimides.
PCT/CN2023/071174 2022-01-11 2023-01-09 Stratifié utile en tant qu'isolation de batterie d'élément à élément WO2023134602A1 (fr)

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Citations (6)

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US20070238008A1 (en) * 2004-08-24 2007-10-11 Hogan Edward J Aerogel-based vehicle thermal management systems and methods
EP2281961A1 (fr) * 2009-06-25 2011-02-09 Knauf Insulation Technology GmbH Aérogel contenant des matériaux composites
FR3033732A1 (fr) * 2015-03-17 2016-09-23 Enersens Materiaux composites multicouches
CN110870395A (zh) * 2017-11-28 2020-03-06 株式会社Lg化学 包含气凝胶的复合绝热片材
CN113646162A (zh) * 2019-02-08 2021-11-12 杜邦安全与建筑公司 适用于电池单元的阻燃隔热材料
CN114421059A (zh) * 2022-01-11 2022-04-29 杜邦(中国)研发管理有限公司 用于电池组单元电池间隔热的层合物

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070238008A1 (en) * 2004-08-24 2007-10-11 Hogan Edward J Aerogel-based vehicle thermal management systems and methods
EP2281961A1 (fr) * 2009-06-25 2011-02-09 Knauf Insulation Technology GmbH Aérogel contenant des matériaux composites
FR3033732A1 (fr) * 2015-03-17 2016-09-23 Enersens Materiaux composites multicouches
CN110870395A (zh) * 2017-11-28 2020-03-06 株式会社Lg化学 包含气凝胶的复合绝热片材
CN113646162A (zh) * 2019-02-08 2021-11-12 杜邦安全与建筑公司 适用于电池单元的阻燃隔热材料
CN114421059A (zh) * 2022-01-11 2022-04-29 杜邦(中国)研发管理有限公司 用于电池组单元电池间隔热的层合物

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