[go: up one dir, main page]

WO2025186643A1 - Barrière thermique - Google Patents

Barrière thermique

Info

Publication number
WO2025186643A1
WO2025186643A1 PCT/IB2025/051415 IB2025051415W WO2025186643A1 WO 2025186643 A1 WO2025186643 A1 WO 2025186643A1 IB 2025051415 W IB2025051415 W IB 2025051415W WO 2025186643 A1 WO2025186643 A1 WO 2025186643A1
Authority
WO
WIPO (PCT)
Prior art keywords
particles
thermal barrier
nonwoven fibrous
thermal
fibers
Prior art date
Legal status (The legal status 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 status listed.)
Pending
Application number
PCT/IB2025/051415
Other languages
English (en)
Other versions
WO2025186643A8 (fr
Inventor
Tien T. Wu
Shailendra B. Rathod
Gerry A. Hoffdahl
Andrew C. CLAUSEN
Jeffrey P. KALISH
Nathan E. Schultz
Michelle M. MOK
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
3M Innovative Properties Co
Original Assignee
3M Innovative Properties Co
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 3M Innovative Properties Co filed Critical 3M Innovative Properties Co
Publication of WO2025186643A1 publication Critical patent/WO2025186643A1/fr
Publication of WO2025186643A8 publication Critical patent/WO2025186643A8/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/413—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties containing granules other than absorbent substances
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/62—Heating or cooling; Temperature control specially adapted for specific applications
    • H01M10/625—Vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/655—Solid structures for heat exchange or heat conduction
    • H01M10/6554—Rods or plates
    • H01M10/6555—Rods or plates arranged between the cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • 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
    • H01M50/289—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

  • the present disclosure relates to a barrier for at least significantly slowing down a thermal runaway event within a battery assembly, e.g., like a battery assembly used in an electric vehicle.
  • Electric motors used in electric or hybrid vehicles are powered, at least in part, by batteries.
  • Lithium-ion batteries are typically used in such applications. These batteries are disposed within the vehicle compactly to save space.
  • the lithium-ion batteries comprise a battery module or assembly of individual battery cells. In an unfortunate circumstance, these batteries may experience a thermal runaway condition, where one of the cells malfunctions due to a variety of reasons and generates a large amount of heat. The heat can get transferred to the adjoining functioning cells and make them malfunction. The heat can also start a fire.
  • the complete battery module can ignite due to the propagation of the heat, eventually engulfing the vehicle, creating a safety hazard to the vehicle, the occupant of the vehicle, and the surroundings of the vehicle.
  • Global regulatory bodies are moving towards enforcing a regulation that would require the battery manufacturers to isolate the malfunctioning cell, thereby avoiding spreading the heat to adjoining cells, and provide the occupants of a vehicle a certain amount of time to evacuate the vehicle.
  • One strategy to meet these requirements is to use a thermal barrier between cells that can delay the thermal runaway propagation.
  • a thermal runaway barrier also needs to provide cushioning properties during the normal application of the battery module.
  • the thermal barrier needs to fit snugly between the cells and occupy the gap between the cells. In other words, the thermal barrier needs to apply a certain pressure on the cell. Further complicating the situation, as the cells age, there is a permanent swelling of cells which translates into a decrease in the gap between the cells over the life of the cell.
  • the thermal barrier needs to meet both the beginning-of-life (BOL) and end-of-life (EOL) pressures exerted by the battery cells, when placed between the cells. If the pressure exerted by the thermal barrier is lower than the required pressures, then the thermal barrier does not fit snugly. If the pressure exerted by the thermal barrier is higher than the required pressures, then the cells can malfunction.
  • BOL beginning-of-life
  • EOL end-of-life
  • WO 2022/024076 Al, WO 2022/024078 Al and WO 2022/024085 Al propose non-woven webs with low thermal conductivity fillers, such as aerogels and fumed silica, dispersed in the web to be used as a thermal runaway barrier to prevent heat from the malfunctioning cell to spread to the other parts of the battery module.
  • the disclosed materials comprise a matrix of inorganic fibers and are thermally stable at temperatures of thermal runaway conditions.
  • a drawback of such non-woven web based thermal barrier is that their compression profile does not meet the requirements for cushioning. Typically, they satisfy requirements for either BOL or EOL pressure, but not both.
  • thermal barrier meets the BOL pressure, then the pressures exerted at EOL by the webs are higher than what is needed. If the thermal barrier meets the EOL pressure, then the pressures exerted at BOL by the webs are lower than what is needed. In other words, the compression curve needs to be flatter. Hence, the compression performance of thermal barriers based on non-woven webs needs to be improved.
  • the present disclosure relates to a thermal barrier for being disposed between battery cells of a battery assembly, said thermal barrier comprising: a layer of a nonwoven fibrous thermal insulation comprising a fiber matrix of inorganic long fibers; a binder dispersed within the fiber matrix so as to hold together the fiber matrix; first particles dispersed within the fiber matrix, wherein the first particles are thermally insulative inorganic particles; an optional organic encapsulation layer encapsulating the layer of nonwoven fibrous thermal insulation; an optional inorganic encapsulation layer encapsulating the layer of nonwoven fibrous thermal insulation; and wherein the thermal barrier further comprises second particles dispersed within the fiber matrix, and wherein the second particles are different from the first particles, and wherein the second particles are organic particles.
  • the present disclosure also relates to a battery cell module for an electric vehicle, said battery cell module comprising: a plurality of battery cells disposed in a housing; and a plurality of thermal barriers as disclosed herein; wherein one thermal barrier is disposed between each pair of adjacent battery cells.
  • the present disclosure also relates to a method of making the thermal barrier disclosed herein, the method comprising: forming a layer of nonwoven fibrous thermal insulation using a wet-laid process or dry -laid process; providing first particles, wherein the first particles are thermally insulative inorganic particles; disposing the first particles so as to be evenly or uniformly distributed throughout or within the layer of nonwoven fibrous thermal insulation; providing second particles, wherein the second particles are different from the first particles, and wherein the second particles are organic particles; and disposing the second particles so as to be evenly or uniformly distributed throughout or within the layer of nonwoven fibrous thermal insulation.
  • the thermal barrier disclosed herein is thermally stable at temperatures of thermal runaway conditions.
  • the thermal barrier disclosed herein has an improved compression performance and meets both the beginning-of-life and end-of-life compression requirements when placed between the battery cells.
  • Figure 1 is a schematic end view of thermal barrier as disclosed herein;
  • Figure 2 is a schematic end view of a battery cell module as disclosed herein, with thermal barriers as disclosed herein disposed between adjacent battery cells;
  • FIG. 4 is a photographic perspective view of a thermal barrier as disclosed herein, the thermal barrier being encapsulated with an adhesive-backed organic polymeric layer with release liners and an expanding gas outlet/notch;
  • Figure 5 is a schematic side view of a dry-laid process for manufacturing a thermal barrier as disclosed herein, according to one embodiment of the present disclosure.
  • the thermal barrier is operatively adapted (i.e., designed, configured, shaped and/or dimensioned) or otherwise suitable for being disposed between adjacent battery cells of a battery module or assembly (i.e., a series of battery cells stacked together in a row) such as that used to power an electric motor (e.g., like that used in an electric or hybrid vehicle).
  • the thermal barrier as disclosed herein may prevent, stop, or can at least significantly slow down a thermal runaway event within the battery module or assembly or between adjacent battery modules or assemblies.
  • a “thermal runaway” is when a battery cell experiences an exothermic chain reaction causing the phenomenon of an uncontrollable temperature rise of the battery cell.
  • the exothermic chain reaction may be caused, for example, by over-heating of the battery cell, over-voltage of the battery cell, and mechanical puncture of the battery cell, among other reasons.
  • a “thermal propagation” is when a battery cell thermal runaway causes the remaining battery cells in a battery module or assembly to undergo the thermal runaway phenomenon.
  • a “thermal runaway event” refers to the overheating of one battery cell, in a battery module or assembly of battery cells, causing a chain reaction of adjacent battery cells overheating, and potentially exploding or catching fire, until the number of overheated battery cells reaches a critical point of propagation resulting in all or more than half of the battery cells in the module or assembly of modules being destroyed.
  • Factors that can cause a battery cell to overheat include: physical damage, applying over voltage, overheating (internal battery cell shorting).
  • the temperature at which the battery cell starts to malfunction decreases.
  • the temperature at which the battery cell starts to malfunction increases. For example, with a controlled ramping up of the temperature, NMC811 type battery cells tend to start malfunctioning or even blow up when the temperature reaches around 120 °C to 130 °C, while NMC622 type battery cells start to malfunction or even blow up when they reach a temperature of around 180 °C.
  • the corresponding temperature is higher for battery cells with lower energy densities (e.g., NMC532 and NMC433 type battery cells).
  • thermal diffusion through the battery cell can result in the localized temperature taking longer to get up to the critical point. It is believed that this thermal diffusion effect can cause the actual temperature at which the battery cell starts to malfunction of blow up to be somewhat higher. It can be desirable for the thermal barrier of the present disclosure to prevent an adjacent battery from reaching a temperature in the range of from about 130 °C up to about 150 °C.
  • “preventing” a thermal runaway event refers to preventing the overheating of a single battery cell from causing the overheating of battery cells that are adjacent to the single battery cell. The thermal barrier is considered to prevent a thermal runaway event, when adjacent battery cells do not reach above 130 °C, 135 °C, 140 °C, 145 °C or 150 °C.
  • thermal runaway event refers to the overheating of a battery cell only causing adjacent battery cells (i.e., three, two or even only one battery cell away on either side of the overheating battery cell) to overheat and the remaining battery cells in the battery module or assembly do not overheat.
  • slowing down athermal runaway event refers to the thermal runaway event being slowed down at least long enough to allow personnel adjacent to the battery module or assembly (e.g., an occupant inside of an electric vehicle passenger compartment) to escape to a safe distance away from the battery module or assembly, before being injured by the thermal runaway event.
  • a battery cell malfunctions e.g., is on fire or overheats to the point of not functioning
  • a thermal barrier is in place between battery cells
  • the time for any adjacent battery cells to propagate the malfunction is at least more than 5 minutes, and preferably more than 10 minutes or even 20 minutes or more.
  • the thermal barrier disclosed herein comprises a layer of a nonwoven fibrous thermal insulation comprising a fiber matrix of inorganic long fibers.
  • the thermal barrier may comprise only one or more layers of a nonwoven fibrous thermal insulation comprising a fiber matrix of inorganic long fibers.
  • the nonwoven fibrous thermal insulation may be dry -laid or wet-laid.
  • the nonwoven fibrous thermal insulation may be in the form of a mat, sheet, strip, or three-dimensional thin-walled structure.
  • inorganic refers to ceramic or otherwise nonmetallic (i.e., not a metal, metal alloy, or metal composite) inorganic material.
  • the inorganic long fibers typically have a mean aspect ratio, i.e., a mean length to diameter ratio, of greater than 2500.
  • the mean aspect ratio of the inorganic long fibers may be from greater than 2500 to up to 70000, or from greater than 2500 to up to 50000, or from 3000 to 70000, or from 3000 to 50000, or from 5000 to 70000, or from 5000 to 50000, or from 8000 to 70000, or from 8000 to 50000.
  • the mean aspect ratio of the inorganic long fibers may also be greater than 70000.
  • the mean aspect ratio is measured by measuring length and diameter of individual fibers on scanning electron micrographs and calculating the aspect ratio, i.e., the length to diameter ratio.
  • the aspect ratio of 50 individual fibers is determined and the average value is calculated.
  • the diameter of the inorganic long fibers may be from 1 to 20 gm.
  • the length of the inorganic long fibers may be from 1 mm to 400 mm, or more.
  • the inorganic long fibers of the fiber matrix may be selected from the group of fibers consisting of alkaline earth silicate fibers, refractory ceramic fibers (RCF), poly crystalline wool (PCW) fibers, basalt fibers, glass fibers, silica fibers, and combinations thereof.
  • Glass fibers and silica fibers typically do not contain any or only nominal shot particles.
  • PCW typically contains a maximum of 5% shot particles
  • alkaline earth silicate (AES) fibers contain up to 60% shot particles when uncleaned and as low as 10% - 30% minimum shot particles when cleaned. Shot particles consist of globular grains that were not turned into fiber during the manufacturing process.
  • the layer of nonwoven fibrous thermal insulation may comprise an amount of inorganic long fibers in the range of from 15 percent by weight to 90 percent by weight, or from 15 percent by weight to 80 percent by weight, or from 15 percent by weight to 70 percent by weight, or from 20 percent by weight to 90 percent by weight, or from 20 percent by weight to 80 percent by weight, or from 20 percent by weight to 70 percent by weight, based on the total weight of the nonwoven fibrous thermal insulation.
  • the layer of nonwoven fibrous thermal insulation of the thermal barrier disclosed herein comprises first particles dispersed within the fiber matrix.
  • the first particles are thermally insulative inorganic particles.
  • the first particles may be dispersed evenly, uniformly, generally or otherwise throughout or to the extent permitted by the manufacturing process (e.g., there can be a little sedimentation of the particles on the bottom of the mat in both the dry laid and wet laid processes) within the fiber matrix.
  • an irreversibly or permanently expanded expandable particle refers to a particle that has been heated to a temperature and for a time that causes the particle to irreversibly or permanently expand to at least 10% and up to 100% of its expandability, either by being pre-expanded before being used to form the thermal barrier, or post-expanded after it is incorporated into the nonwoven fibrous thermal insulation.
  • Intumescent particles can be permanently expanded by overheating the particles to beyond the point of reversibility (e.g., in the range of from about 350 °C up to about 1000 °C for vermiculite).
  • a permanently expanded intumescent particle e.g., vermiculite particle
  • the degree of permanent expansion of the particle increases (i.e., the particles can get larger and/or longer).
  • vermiculite that has been permanently expanded by a chemical treatment method
  • a chemical treatment method see, e.g., “Chemical Exfoliation of Vermiculite and the Production of Colloidal Dispersions”, G.F. Walker, W.G. Garrett, Science 21Aprl967: Vol. 156, Issue 3773, pp. 385-387, DOI: 10.1126/science.l56.3773.385; and https://science.sciencemag.org/content/156/3773/385.abstract).
  • the expanded intumescent particles are not oriented primarily in the plane of the insulation.
  • Unexpanded intumescent particles typically have a more uniform structural geometry (i.e., have an aspect ratio closer to 1) compared to the same particles in its expanded state. It is believed that this more uniform structural geometry is less likely to be influenced by the alignment of the inorganic long fibers during the formation of the nonwoven fibrous thermal insulation. As a result, the postexpanded intumescent particles are more likely to be oriented isotropically within the nonwoven fibrous thermal insulation.
  • the elongated particles can become aligned in the thickness direction (i.e., z-axis), in plane (i.e., x-axis, y-axis, and/or therebetween), or off-axis thereof. It is believed this difference between the orientation of pre-expanded particles versus post-expanded particles is caused by the unexpanded particles having a more uniform structural geometry than that exhibited while in their expanded state.
  • the layer of nonwoven fibrous thermal insulation may comprise the first particles in an amount of at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35% by weight, based on the total weight of the nonwoven fibrous thermal insulation.
  • the layer of nonwoven fibrous thermal insulation may comprise the first particles in an amount of up to 40%, or up to 45%, or up to 50%, or up to 55%, or up to 60% by weight, based on the total weight of the nonwoven fibrous thermal insulation.
  • a particle content as high as 60% by weight can be achieved using a dry -laid process, and as high as 50% by weight using a wet-laid process.
  • the layer of nonwoven fibrous thermal insulation may comprise the first particles in an amount of from 10 percent by weight to 60 percent by weight, based on the total weight of the nonwoven fibrous thermal insulation.
  • the layer of nonwoven thermal insulation of the thermal barrier disclosed herein comprises a binder dispersed within the fiber matrix so as to hold together the fiber matrix.
  • the binder may be an organic or inorganic binder, e.g., an organic or inorganic adhesive binder, organic or inorganic binder fibers that are needle punched, stitched or otherwise mechanically entangled into the fiber matrix so as to hold together the fiber matrix.
  • the binder may be dispersed evenly, uniformly, generally or otherwise throughout or to the extent permitted by the manufacturing process within the fiber matrix so as to bond together the inorganic long fibers and first and second particles or otherwise hold together the fiber matrix for as long as needed to at least survive the degree of handling required (e.g., during the encapsulation process) before being installed between battery cells.
  • Inorganic binders, organic binders, or a combination of both can be useful according to the present disclosure and may include, e.g., those disclosed in US 8,834,759.
  • An example of an inorganic binder useful in both dry -laid or wet-laid fiber processing can include particles of silicone that convert to fusible silica when heated.
  • An organic -inorganic hybrid binder may also be useful such as, e.g., available under the trade designation “Wacker MQ 803 TF”, which is a co-hydrolysis product of tetra-alkoxy silane (Q unit) and trimethyl-alkoxy silane (M unit).
  • Wacker MQ 803 TF The chemical structure of Wacker MQ 803 TF can be seen as a three dimensional network of poly silicic acid units which are end-blocked with trimethylsilyl groups. Some residual ethoxy and hydroxy functions are present.
  • the average molecular weight can be exactly controlled by the ratio of M and Q units. This ratio approximately is 0.67 for Wacker MQ 803 TF.
  • the binder dispersed within the fiber matrix may be in the form of polymer fibers.
  • the binder may be in the form of bicomponent core-sheath polymer fibers, such as core-sheath polyester/polyethylene fibers.
  • the polymer fiber binder does not lose its fibrous form during the process of making the thermal barrier.
  • Exemplary binder fibers include the use of bicomponent core-sheath polymeric fibers in a dry -laid process.
  • ethylene vinyl acetate latex dispersion binder, bicomponent core-sheath polymeric fibers, or a combination of both can be used.
  • the binder can be activated by heating and compressing the nonwoven fibrous thermal insulation material.
  • a combination of organic and inorganic binder can also be used.
  • the organic binders as used for the thermal barrier disclosed herein may be in the form of polymer fibers (e.g., PE/PET, PET, FRPET, such as those available under the trade designation “T255” from Trevira), dry polymer powder (e.g., LDPE, polyamide, epoxy resin powder (available under the trade designation “3M Scotchcast 265”, “3M Scotchkote 6258” available from 3M Co., St. Paul, MN)), or a liquid binder (e.g., acylic latex, ethylene vinyl acetate (EAF68) latex, silicone, polyurethane etc.).
  • PE/PET polymer fibers
  • PET PET
  • FRPET such as those available under the trade designation “T255” from Trevira
  • dry polymer powder e.g., LDPE, polyamide, epoxy resin powder (available under the trade designation “3M Scotchcast 265”, “3M Scotchkote 6258” available from 3M Co.,
  • the layer of nonwoven fibrous thermal insulation may comprise the binder in an amount of at least 2.5%, at least 3.0%, at least 4.0%, at least 4.5%, at least 5.0%, at least 5.5%, at least 6.0%, or at least 6.5% by weight, based on the total weight of the nonwoven fibrous thermal insulation.
  • the layer of nonwoven fibrous thermal insulation may comprise the binder in an amount of up to 7.0%, up to 7.5%, up to 8.0%, up to 8.5%, up to 9.0%, up to 9.5%, up to 10%, up to 15%, or up to 20% by weight, based on the total weight of the nonwoven fibrous thermal insulation.
  • the layer of nonwoven fibrous thermal insulation may comprise the binder in an amount of from 2.5% by weight to 15% by weight, or from 2.5% by weight to 20% by weight, based on the total weight of the nonwoven fibrous thermal insulation.
  • the layer of nonwoven fibrous thermal insulation of the thermal barrier disclosed herein further comprises second particles dispersed within the fiber matrix.
  • the second particles are different from the first particles.
  • the second particles are organic particles.
  • the organic particles that may be used as second particles may be elastomeric particles.
  • the organic particles may be elastomeric particles selected from the group consisting of rubber particles, silicone particles, polyurethane particles, styrenic block copolymer particles, and combinations thereof.
  • the organic particles may also be foam particles, such as silicone foam particles, polyurethane foam particles, polyolefin foam particles, thermoset foam particles, polyethersulfone foam particles, or other organic foam particles.
  • the particle size of the organic particles is up to 10 mm and may be from 1 pm to 10 mm, or from 10 pm to 10 mm, or from 100 pm to 10 mm, or from 1 mm to 10 mm, as measured by sieve analysis.
  • the median particle size (dso) of the organic particles is from 1 pm to up to 500 pm, or from 1 pm to up to 250 pm.
  • the median particle size (dso) may be measured by laser diffraction
  • the shape of the organic particles may be spherical or irregular or any other shape.
  • the layer of nonwoven fibrous thermal insulation may comprise the second particles in an amount of from 3 to 50 percent by weight, or from 3 to 30 percent by weight, or from 3 to 25 percent by weight, or from 3 to 20 percent by weight, based on the total weight of the nonwoven fibrous thermal insulation. In some embodiments, the layer of nonwoven fibrous thermal insulation may comprise the second particles in an amount of from 3 to 20 percent by weight, based on the total weight of the nonwoven fibrous thermal insulation.
  • the second particles that are comprised in the layer of nonwoven fibrous thermal insulation of the thermal barrier disclosed herein have the function of affecting compression performance of the thermal barrier and may also be referred to as “compression performance affecting particles”.
  • compression performance affecting particles This means that the thermal barrier is more compressible due to the addition of the second particles, or, in other words, the thermal barrier can be compressed to a higher extent with less pressure exerted on the thermal barrier.
  • the pressure exerted by the thermal barrier on an adjacent battery cell in an installed (i.e., compressed) condition is decreased as compared to a thermal barrier not comprising the second particles.
  • This can also be described as “flattening of the pressure versus relative compression curve” of the thermal barrier with respect to the respective curve for a thermal barrier without addition of the second particles. Due to the improved compressibility, the thermal barrier is able to meet both the beginning-of-life and end- of-life compression requirements when placed between the battery cells.
  • the thermal barrier disclosed herein is compressible.
  • the thermal barrier may be compressible at least 10%, or by at least 20%, or by at least 30%, or by at least 35%, or by at least 40%, or by at least 50%, or by at least 60%, or by at least 70%, or by at least 75%, in direction of compression with an axial pressure of at most 3 MPa.
  • the thermal barrier may be compressible at least 10%, or by at least 20%, or by at least 30%, or by at least 35%, or by at least 40%, or by at least 50%, or by at least 60%, or by at least 70%, or by at least 80%, or by at least 90%, or by up to 95%, in direction of compression with an axial pressure of at most 25 MPa.
  • thermal barrier materials of the present disclosure should be thermally stable at temperatures of thermal runaway conditions thus, in some embodiments, the amount of organic material present in the thermal barrier may be less than 50, 45, 40, 35, 30, 25, 20, or even 15 wt.%.
  • the thermal barrier exhibits a pressure in an installed (i.e., compressed) condition on an adjacent battery cell.
  • the pressure exhibited by the thermal barrier disclosed herein is lower than the pressure exhibited by a thermal barrier comprising a layer of a nonwoven fibrous thermal insulation of the same composition but without the addition of the second particles.
  • the pressure exhibited by the thermal barrier disclosed herein in an installed (i.e., compressed) condition is at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 45%, or at least 50% lower than the pressure exhibited by a thermal barrier comprising a layer of a nonwoven fibrous thermal insulation of the same composition but without the addition of the second particles.
  • the pressure exhibited by the thermal barrier disclosed herein is up to 60% lower than the pressure exhibited by a thermal barrier comprising a layer of a nonwoven fibrous thermal insulation of the same composition but without the addition of the second particles.
  • This decrease in pressure exhibited by the thermal barrier can be observed when both the pressure exhibited by the thermal barrier disclosed herein and by a thermal barrier without the addition of the second particles are measured at the same relative axial compression and the same sample thickness for the uncompressed and compressed thermal barriers, i.e., when both the pressure exhibited by the thermal barrier disclosed herein and by a thermal barrier without the addition of the second particles are measured at the same gap by the Compression Performance Test Method as described in the Examples Section.
  • thermal barrier This decrease in pressure exhibited by the thermal barrier disclosed herein, as compared to a thermal barrier without the addition of the second particles, can be observed when the thermal barrier is axially compressed by 10 to 95% in direction of compression with an axial pressure of at most 25 MPa, or by 10 to 75% in direction of compression with an axial pressure of at most 3 MPa.
  • the thermal barrier is compressed as a result of the expansion of the battery cells, due to swelling of the battery cells as the cells age.
  • a cyclic compression test can be performed to measure the performance of the thermal barrier upon repeated application of compression.
  • the thermal barriers of the present disclosure have an improved beginning of life and end of life performance.
  • the average beginning-of-life is at least 25, 30, 40, 50, 75, 100, 500, or even 100 kPa.
  • the average end-of-life is at most 2000, 1800, or even 1600 kPa.
  • the layer of nonwoven fibrous thermal insulation may have an installed (i.e., compressed) thickness in the range of from 0.5 mm up to 5.0 mm.
  • the installed (i.e., compressed) thickness may be in the range of from 0.5 mm up to 2.5 mm, where the lower limit can be about 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, or 1.5 mm, and the upper limit can be about 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2.0 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, or 2.5 mm.
  • the installed thickness may even be as high as about 2.6 mm, 2.7 mm, 2.8 mm, 2.9 mm, 3.0 mm, 3.1 mm, 3.2 mm, 3.3 mm, 3.4 mm, 3.5 mm, 3.6 mm, 3.7 mm, 3.8 mm, 3.9 mm, 4.0 mm, 4.1 mm, 4.2 mm, 4.3 mm, 4.4 mm, 4.5 mm, 4.6 mm, 4.7 mm, 4.8 mm, 4.9 mm, or 5.0 mm.
  • the installed thickness of the layer of nonwoven fibrous thermal insulation is almost always less than its uninstalled (i.e., uncompressed) thickness.
  • the performance of the thermal barrier is measured when it is in its installed (i.e., compressed) condition.
  • the layer of nonwoven fibrous thermal insulation may have an uninstalled (i.e., uncompressed) thickness in the range of from 1.0 mm to up to 8.0 mm, where the lower limit can be about 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2.0 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, 2.5 mm, 2.6 mm, 2.7 mm, 2.8 mm, 2.9 mm, 3.0 mm, 3.1 mm, 3.2 mm, 3.3 mm, 3.4 mm, or 3.5 mm, and the upper limit can be about 4.0 mm, 4.1 mm, 4.2 mm, 4.3 mm, 4.4 mm, 4.5 mm, 4.6 mm, 4.7 mm, 4.8 mm, 4.9 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5
  • the layer of nonwoven fibrous thermal insulation has a weight per square meter in the range of from 250 g/m 2 up to 1400 g/m 2 .
  • the weight per square meter can be desirable for the weight per square meter to be in the range of from about 250 g/m 2 to about 400 g/m 2 (e.g., 300 g/m 2 , 350 g/m 2 ) for a gap between adjacent battery cells in the range of from about 0.75 mm up to about 1.25 mm.
  • the weight per square meter can also be desirable for the weight per square meter to be in the range of from about 300 g/m 2 up to about 550 g/m 2 for a gap between adjacent battery cells in the range of from about 0.75 mm up to about 2.5 mm.
  • the weight per square meter can be in the range of from about 600 g/m 2 up to about 1400 g/m 2 (e.g., 650 g/m 2 , 700 g/m 2 , 750 g/m 2 , 800 g/m 2 , 900 g/m 2 , 950 g/m 2 , 1000 g/m 2 , 1050 g/m 2 , 1100 g/m 2 , 1150 g/m 2 , 1200 g/m 2 , 1250 g/m 2 , 1300 g/m 2 , 1350 g/m 2 , 1400 g/m 2 ).
  • the thermal barrier disclosed herein may optionally further comprise an organic encapsulation layer encapsulating the layer of nonwoven fibrous thermal insulation.
  • the optional organic encapsulation layer may be a polymeric layer or a paper layer.
  • the organic encapsulation layer may be, e.g., one layer or multiple opposing sandwiching layers, with each layer being in the form of a film, coating, organic fibrous nonwoven or woven fabric.
  • the organic encapsulation layer may enclose or otherwise encapsulate all of, a majority of or a portion of at least one or both major faces and preferably also all of, a majority of or a portion of the peripheral edge of the layer of nonwoven fibrous thermal insulation so as to prevent or significantly reduce the shedding or loss of fibers or particles from the encapsulated layer of nonwoven fibrous thermal insulation.
  • the thermal barrier disclosed herein may optionally further comprise an inorganic encapsulation layer encapsulating the layer of nonwoven fibrous thermal insulation.
  • the optional inorganic encapsulation layer may be, e.g., glass fiber woven fabric of 25 - 80 g/m 2 .
  • the inorganic encapsulation layer may be, e.g., one layer or multiple opposing sandwiching layers, with each layer being in the form of an inorganic coating or fibrous nonwoven or woven fabric.
  • the inorganic encapsulation layer may enclose or otherwise encapsulate all of, a majority of or a portion of at least one or both major faces and preferably also all of, a majority of or a portion of the peripheral edge of the layer of nonwoven fibrous thermal insulation so as to prevent or significantly reduce the shedding or loss of fibers or particles from the encapsulated layer of nonwoven fibrous thermal insulation.
  • the reduction of inorganic fiber or particle shedding is significant, when the number of inorganic fibers or particles lost is less than 10%, 5% or 1% by weight percent of the original fiber or particle content of the layer of nonwoven fibrous thermal insulation.
  • the thinner the organic encapsulation layer i.e., the lower the organic content of the barrier) the better the hot/cold test results.
  • the thermal barrier may be provided as a thermal barrier assembly comprising a plurality of the thermal barriers as disclosed herein, wherein the plurality of thermal barriers are provided (a) in a container (e.g., a cardboard or other box) in the form of a stack, (b) disposed end-to-end in series, with one major face of each thermal barrier being adhered onto a major adhesive surface of a length of single-sided or doublesided adhesive tape (when a double-sided adhesive tape is used, the opposite major adhesive surface of the tape can be protected by a release liner), or (c) disposed end-to-end in series in the form of a tape, with the one or more layers of nonwoven fibrous thermal insulation of each thermal barrier being disposed end-to- end and sandwiched or otherwise encapsulated between two opposing lengths of organic (e.g., polymeric) encapsulation layers (e.g., in the form of two opposing films, coatings, fibrous fabrics, etc.).
  • a container e.g., a
  • a method of making the thermal barrier disclosed herein comprising: forming a layer of nonwoven fibrous thermal insulation using a wet-laid process or dry -laid process; providing first particles, wherein the first particles are thermally insulative inorganic particles; disposing the first particles so as to be evenly or uniformly distributed throughout or within the layer of nonwoven fibrous thermal insulation; providing second particles, wherein the second particles are different from the first particles, and wherein the second particles are organic particles; and disposing the second particles so as to be evenly or uniformly distributed throughout or within the layer of nonwoven fibrous thermal insulation.
  • the process step of forming a layer of nonwoven fibrous thermal insulation using a wet-laid process or dry- laid process comprises providing inorganic long fibers; providing a binder; and mixing the inorganic long fibers and the binder.
  • the inorganic long fibers, the binder, the first particles and the second particles as described above for the thermal barrier may be used for making the thermal barrier disclosed herein.
  • a layer of a nonwoven fibrous thermal insulation 10 comprising an inorganic fiber matrix, a binder, and first and second particles.
  • the layer of a nonwoven fibrous thermal insulation 10 is encapsulated with an organic or inorganic layer 12.
  • an exemplary battery cell module 20 includes a plurality of battery cells 22 and a plurality of thermal barriers 24.
  • Each thermal barrier 24 can be in the form of one or more layers of a nonwoven fibrous thermal insulation 10, with or without an encapsulation layer 12, and that can be made from the exemplary materials described herein.
  • a thermal barrier 24 can be disposed between adjacent battery cells 22, between groups of cells 22, or both, at one or more locations throughout the batter cell module 20.
  • the battery cell module 20 rests above a cooling plate 26 and a tray 28.
  • an exemplary battery pack 30 includes a plurality of battery cell modules 20, which may each have its own cooling plate 26 and tray 28 or all of the modules 20 may share the same cooling plate 26 and tray 28.
  • a thermal barrier 24, formed from the exemplary materials described herein, can be disposed between one or more or all adjacent battery cell modules 20, on the top of one or more or all of the battery cell modules 20 (see reference number 24’), or any combination of both.
  • a single or multiple thermal barriers 24 may also be dimensioned so as to cover the tops of all of the battery cell modules 20.
  • an exemplary thermal barrier 24 includes one or more fiber matrix layers (not shown) encapsulated with an organic or inorganic layer 12 that covers both sides and the peripheral edge of the one or more layers of a nonwoven fibrous thermal insulation.
  • the major opposite faces of the encapsulating layer 12 are coated with an adhesive (e.g., a pressure sensitive adhesive) protected by corresponding release liners 14 and 16.
  • the encapsulating layer 12 prefferably includes one or more outlets or openings 18 (e.g., in the form of a notch) that allows air (e.g., hot air) or other gases to escape from inside the encapsulation layer 12 to swell and expand like a balloon, e.g., when the air trapped in the encapsulation layer 12 is heated to an elevated temperature (e.g., when the temperature of one or more of the adjacent battery cells 20 increases).
  • air e.g., hot air
  • an elevated temperature e.g., when the temperature of one or more of the adjacent battery cells 20 increases.
  • a conventional dry-laid manufacturing equipment and processes can be used to manufacture thermal barriers as disclosed herein. Examples of such equipment and processes can be found described in U.S. Pat. Nos. 9,580,848 (Henderson et al.), 9,475,034 (Vincent et al.), 7,491,354 (Anderson), and 6,808,664 (Falk et al.).
  • Such equipment can include a chamber or forming box 40 with multiple feeder inlets, including an inlet 42 for feeding any desired combination of matrix fibers (inorganic long fibers) and binder into the box 40, and multiple inlets 44, 44’ and 44” for feeding the first and second particles into the box 40.
  • the resulting nonwoven fibrous material 45 is deposited onto a belt 46 that conveys the material 45 into, through and out of a baking oven 47 where the binder is cured at least so that the fibrous material 45 can be further processed.
  • the resulting cured nonwoven fibrous material 45’ is then die-cut, laser-cut, water-jet cut, or otherwise processed into individual nonwoven fiber layers 10 (not shown), which are then processed at an encapsulation station 48, e.g., by having a polymeric film 12 (not shown) laminated to opposite sides of a single layer 10 or a stack of two or more layers 10.
  • An optional hot melt adhesive or pressure sensitive adhesive can be applied to one or both sides of the encapsulate 12 at corresponding spray stations 49 and 49’.
  • a protective release liner (not shown) can be subsequently applied to each adhesive surface.
  • a thermal barrier can be made using at least one dilute (desirably, not over 5 percent solids by weight) aqueous slurry containing inorganic long fibers, binder and first and second particles, by depositing the aqueous slurry onto a permeable substrate, such as a screen or a “wire” of a paper making machine, partially dewatering the slurry by gravity and/or vacuum and then pressing to increase the density (e.g., with pressure rollers). The thermal barrier is then fully dried with heated rollers.
  • a permeable substrate such as a screen or a “wire” of a paper making machine
  • a battery cell module for an electric vehicle, the battery cell module comprising: a plurality of battery cells disposed in a housing; and a plurality of thermal barriers as disclosed herein, wherein one thermal barrier is disposed between each pair of adjacent battery cells.
  • a plurality of battery cell modules may be included in a battery pack.
  • the compression test is performed using a tensile tester from Instron, Norwood, MA, USA in compression mode.
  • the sample was cut into squares with 4 inch (10.16 cm) sides and a thickness greater than 3 millimeters.
  • the test was performed at about 23 °C.
  • the upper plate of the compression tester was moved with a speed of 300 mm/min to a gap of 3.5 mm. After holding the gap for 5 min, the sample was cyclically compressed by 0.5 mm at 10 pm/s and decompressed by 0.4 mm at 10 pm/s. The cyclical compression was repeated until a maximum pressure of 3 MPa or a minimum gap of 1.6 mm.
  • the compression force (in kPa) was recorded for each maximum and minimum peak of each cycle.
  • the minimum open-gap pressure or beginning of life (BOL) pressure of the entire test reported was as P(BOL).
  • the maximum pressure at 1.8 mm gap or end of life (EOL) pressure was reported as the P(EOL).
  • Two-inches diameter samples having a height of 8 mm were weighed on a weighing balance and the weight was divided by the area of the sample.
  • the base weight of all samples was in the range of 1050 to 1370 g/m 2 .
  • an 80:20 by weight blend of the SUPERWOOL (inorganic long fibers) and T-255 fibers (binder) were weighed and premixed by hand before placing on top of a feeding belt.
  • the fiber material was processed (i.e., fed from the top) through an air-laid processer, like that disclosed in US Patent No. 7,491,354, where the fibers were opened and dispersed into an air stream, then collected on a screen belt. Details of such air-laid (or dry -laid) processing apparatus and methods of using such apparatus in forming air-laid webs can be found described in U.S. Pat. Nos.
  • the blended fibers from the first step above were placed on the feeding belt of the air-laid processor for a second pass, during which CAB-O-SIL particles (first particles) were top or side fed into the chamber or forming box of the air-laid processor.
  • a volumetric feeder coupled with an air-driven horn was used to distribute the fillers uniformly into the resulting web.
  • the weight ratio of the SUPERWOOL and T-255 fibers blend to CAB-O-SIL was 1: 1. While there was no need to dry, the resulting web went through a forced-air convection oven at 290 °F at a speed of 1.1 m/min to activate the bi-component fibers (T-255) and bond the web together.
  • the webs were, then, densified to a specified height using a hot press set with a gap set at the specified height.
  • the samples were placed between two hot plates of the hot press maintained at 300 °F (149 °C).
  • a pre-determined amount of pressure was applied for a pre-determined amount of time to activate the bicomponentfibers (T-255).
  • the densified sample was immediately placed between two plates maintained at room temperature under a pre-determined pressure for a pre-determined time, to lock the web down to the desired thickness.
  • the pressure and time during the heating step were tuned to get to the desired thickness. For example, to obtain an 8-mm final thickness, 1500 Ibf (680 kgf; applied on an area of 250 mm x 100 mm) for 1 minute was used. For all Examples 1-10 and Comparative Example 1, the final thickness of the thermal barrier was 8 mm.
  • Comparative Example 1 (CEX1) was prepared as described above in the general method for preparing thermal barrier.
  • Example 1 (EXI) was prepared in the same manner as described above in the general method for preparing thermal barrier, except that compression performance affecting particles (second particles; MRP 200 particles fine grade) were added as further filler particles to the feeding belt to the SUPERWOOL and T- 255 fiber blend along with the CAB-O-SIL particles in the second step of air laid processing.
  • the amount of MRP 200 in the final product was 20% by weight.
  • the amount of SUPERWOOL and T-255 fiber blend 80:20 in the final product was 40 wt.-%, the amount of CAB-O-SIL particles in the final product was 40 wt.-%.
  • CEX1 and EXI were tested for their compression performance using the test method described above and the results are shown in Table 1.
  • Examples 2 to 9 were prepared in the same manner as EXI except that the type and amount of compression performance affecting particles were varied as summarized in Table 1. EX2 to EX9 were tested for their compression performance using the test method described above and the results are shown in Table 1.
  • Example 10 Example 10 (EX10) was prepared in the same manner as EXI except that the compression performance effecting particles were KRATON D 1111. The amount of KRATON D 1111 in the final product was 10% by weight. The amount of SUPERWOOL and T-255 fiber blend 80:20 in the final product was 45 wt.-%, the amount of CAB-O-SIL particles in the final product was 45 wt-%. EX10 was tested for its compression performance using the test method described above and the results are shown in Table 1.
  • a testing gap of 4mm corresponds to a compression of 50% for the sample of 8 mm height
  • a testing gap of 2mm corresponds to a compression of 75% for the sample of 8 mm height
  • the pressure exhibited by the thermal barrier disclosed herein is lower than the pressure exhibited by a thermal barrier of the same composition but without the addition of the second particles, when tested at the same testing gap.
  • Comparative Example 2 (CEX2) was prepared as described above in the general method for preparing thermal barrier except the web was not densified and the amount of components used is listed in Table 2. The materials were run targeting a total basis weight of 1050 gsm. The Cyclic Compression Test Method was mn on the sample and the result was reported in Table 2.
  • Example 11 was prepared in the same manner as described above in the general method for preparing thermal barrier, except that compression performance affecting particles (second particles; Infinergy MP240) were added as further filler particles to the feeding belt to the SUPERWOOL and T-255 fiber blend along with the CAB-O-SIL particles in the second step of air laid processing and the web was not densified.
  • the weight percent of the components used are shown in Table 2.
  • the materials were run targeting a total basis weight of 1050 gsm.
  • the Cyclic Compression Test Method was run on the sample and the result is reported in Table 2.
  • the web was densified using a Glenro dual belt compression oven. The webs were densified at 200 °C, 1 m/min, and with 30000 N of force. These densified samples were tested using the the Cycle Compression Test Method and the average results from two samples are reported in Table 2.
  • Example 12 (EX, 12) was prepared in the same manner as described above in the general method for preparing thermal barrier, except that compression performance affecting particles (second particles; Neopolen P 9270) were added as further filler particles to the feeding belt to the SUPERWOOL and T- 255 fiber blend along with the CAB-O-SIL particles in the second step of air laid processing and the web was not densified.
  • the weight percent of the components used are shown in Table 2.
  • the materials were run targeting a total basis weight of 1050 gsm.
  • the web was densified using the Glenro dual belt compression oven.
  • the webs were densified at 200 °C, 1 m/min, and with 30000 N of force. These densified samples were tested using the the Cycle Compression Test Method and the average results from two samples are reported in Table 2.
  • Table 2 Table 2

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • Battery Mounting, Suspending (AREA)
  • Secondary Cells (AREA)

Abstract

La présente invention concerne une barrière thermique destinée à être disposée entre des éléments de batterie d'un ensemble batterie, ladite barrière thermique comprenant : une couche d'une isolation thermique fibreuse non tissée comprenant une matrice fibreuse de fibres longues inorganiques ; un liant dispersé à l'intérieur de la matrice fibreuse de façon à maintenir ensemble la matrice fibreuse ; des premières particules dispersées à l'intérieur de la matrice fibreuse, les premières particules étant des particules inorganiques thermiquement isolantes ; une couche d'encapsulation organique facultative encapsulant la couche d'isolation thermique fibreuse non tissée ; et une couche d'encapsulation inorganique facultative encapsulant la couche d'isolation thermique fibreuse non tissée ; la barrière thermique comprenant en outre des secondes particules dispersées à l'intérieur de la matrice fibreuse, et les secondes particules étant différentes des premières particules et les secondes particules étant des particules organiques ; et la barrière thermique étant compressible. La présente invention concerne en outre un procédé de fabrication de ladite barrière thermique et un module d'élément de batterie pour un véhicule électrique, le module d'élément de batterie comprenant une pluralité d'éléments de batterie disposés dans un boîtier et une pluralité desdites barrières thermiques.
PCT/IB2025/051415 2024-03-04 2025-02-11 Barrière thermique Pending WO2025186643A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202463560915P 2024-03-04 2024-03-04
US63/560,915 2024-03-04

Publications (2)

Publication Number Publication Date
WO2025186643A1 true WO2025186643A1 (fr) 2025-09-12
WO2025186643A8 WO2025186643A8 (fr) 2025-10-02

Family

ID=94734152

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2025/051415 Pending WO2025186643A1 (fr) 2024-03-04 2025-02-11 Barrière thermique

Country Status (1)

Country Link
WO (1) WO2025186643A1 (fr)

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6458418B2 (en) 1997-02-06 2002-10-01 3M Innovative Properties Company Method of making multilayer sheets for firestops or mounting mats
US6808664B2 (en) 2000-05-22 2004-10-26 Sca Hygiene Products Ab Method of forming an air laid fibrous web
US7491354B2 (en) 2003-11-07 2009-02-17 Formfiber Denmark Aps Fiber distribution device for dry forming a fibrous product and method
US8834759B2 (en) 2010-04-13 2014-09-16 3M Innovative Properties Company Inorganic fiber webs and methods of making and using
US9475034B2 (en) 2010-04-22 2016-10-25 3M Innovative Properties Company Nonwoven fibrous webs containing chemically active particulates and methods of making and using same
US9580848B2 (en) 2011-12-30 2017-02-28 3M Innovative Properties Company Apparatus and methods for producing nonwoven fibrous webs
WO2022024085A1 (fr) 2020-07-30 2022-02-03 3M Innovative Properties Company Barrière d'emballement thermique d'élément de batterie
WO2024187089A1 (fr) * 2023-03-09 2024-09-12 3M Innovative Properties Company Élasticité de barrière thermique améliorée
EP4459751A1 (fr) * 2021-12-28 2024-11-06 Ibiden Co., Ltd. Feuille de suppression de transfert thermique, et ensemble batterie

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6458418B2 (en) 1997-02-06 2002-10-01 3M Innovative Properties Company Method of making multilayer sheets for firestops or mounting mats
US6808664B2 (en) 2000-05-22 2004-10-26 Sca Hygiene Products Ab Method of forming an air laid fibrous web
US7491354B2 (en) 2003-11-07 2009-02-17 Formfiber Denmark Aps Fiber distribution device for dry forming a fibrous product and method
US8834759B2 (en) 2010-04-13 2014-09-16 3M Innovative Properties Company Inorganic fiber webs and methods of making and using
US9475034B2 (en) 2010-04-22 2016-10-25 3M Innovative Properties Company Nonwoven fibrous webs containing chemically active particulates and methods of making and using same
US9580848B2 (en) 2011-12-30 2017-02-28 3M Innovative Properties Company Apparatus and methods for producing nonwoven fibrous webs
WO2022024085A1 (fr) 2020-07-30 2022-02-03 3M Innovative Properties Company Barrière d'emballement thermique d'élément de batterie
WO2022024078A1 (fr) 2020-07-30 2022-02-03 3M Innovative Properties Company Barrière d'emballement thermique d'élément de batterie
WO2022024076A1 (fr) 2020-07-30 2022-02-03 3M Innovative Properties Company Barrière d'emballement thermique d'élément de batterie
EP4459751A1 (fr) * 2021-12-28 2024-11-06 Ibiden Co., Ltd. Feuille de suppression de transfert thermique, et ensemble batterie
WO2024187089A1 (fr) * 2023-03-09 2024-09-12 3M Innovative Properties Company Élasticité de barrière thermique améliorée

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
G.F. WALKERW.G. GARRETT: "Chemical Exfoliation of Vermiculite and the Production of Colloidal Dispersions", SCIENCE, vol. 156, no. 3773, 21 April 1967 (1967-04-21), pages 385 - 387

Also Published As

Publication number Publication date
WO2025186643A8 (fr) 2025-10-02

Similar Documents

Publication Publication Date Title
JP7785062B2 (ja) 電池セル熱暴走バリア
US7226656B2 (en) Thermoformable acoustic sheet
JP2022506006A (ja) 防火物品及び関連する方法
TW202320390A (zh) 用於控制能量儲存系統中熱失控事件之排放氣體和噴射物之裝置、系統及方法
KR101363423B1 (ko) 팽창 퍼라이트·실리카 성형 구조체를 갖는 저밀도 무기질 파우더 진공단열재, 이의 제조 방법 및 이의 성형기
TW202319232A (zh) 用於緩解電能儲存熱事件之材料、系統及方法
JP2002333092A (ja) 繊維・微粒子複合断熱材
JP2015530340A (ja) 膨張パーライトを用いた低密度無機質パウダー断熱材の製造方法及び成形機
WO2024187089A1 (fr) Élasticité de barrière thermique améliorée
WO2025186643A1 (fr) Barrière thermique
WO2023248133A1 (fr) Article pourvu de propriétés de gestion de pression et d'isolation thermique
US20240165929A1 (en) Biomass-derived polymer and cellulose material composition for insulation
WO2024261693A1 (fr) Article doté de propriétés d'isolation thermique
WO2024100559A1 (fr) Produit barrière contre l'emballement thermique avec nouvelle encapsulation
WO2025083575A1 (fr) Article doté de propriétés d'isolation thermique
CN222261203U (zh) 保护盖罩以及电池模块
AU2010233029B2 (en) A thermoformable acoustic sheet
KR20250024812A (ko) 열 폭주 관리를 위하여 전기 자동차 배터리에서 사용되는 팽창성 시트
WO2025191405A1 (fr) Substrat non tissé à pénétrations de mousse individuelles
JP2024079119A (ja) 熱伝達抑制シート及び組電池
AU2006101037B4 (en) Thermoformable acoustic articles
AU2006101035A5 (en) A motor vehicle including a thermoformed acoustic article

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 25707468

Country of ref document: EP

Kind code of ref document: A1