A method for preparing a single-sided flush aerogel thermal insulation pad with core material and U-shaped frame

Abstract

This invention discloses a method for preparing a single-sided flush aerogel heat insulation pad with a core material and a U-shaped frame. The steps are as follows: A concave-convex mold is installed on a vacuum hot press. The concave-convex mold includes an upper mold and a lower mold. The upper mold has at least one groove on its end face facing the lower mold, and the lower mold has at least one boss on its end face facing the upper mold. The groove and the boss correspond one-to-one to form the core material extrusion area. The width of the groove is less than the width of the U-shaped frame, and the length of the groove is less than the length of the U-shaped frame. A material is laid on a material board. The laid material board is placed in the lower mold, with the core material extrusion area corresponding to the aerogel core material. Vacuum hot pressing is performed, during which the upper mold moves towards the lower mold, causing the aerogel core material to be extruded into the groove. The aerogel heat insulation pad obtained by this invention has a core material end face flush with one side of the U-shaped frame, which strengthens the effective contact area between the flush-faced backing adhesive and the battery pack, increases the adhesion between the heat insulation pad and the battery pack, and reduces the risk of double-sided adhesive bubbling of the heat insulation pad.

Description

Technical Field

[0001] This invention belongs to the field of aerogel thermal insulation pad preparation technology, specifically relating to a method for preparing an aerogel thermal insulation pad with the core material and the U-shaped frame flush on one side. Background Technology

[0002] With the continuous increase in sales of new energy vehicles, global users are increasingly competing on cost while ensuring driving range and battery safety. Currently, the commonly used heat insulation pads with U-shaped frames have both ends of the core material recessed within the U-shaped frame. This is because during vacuum hot-pressing lamination, the two ends of the core material are recessed within the U-shaped frame. Due to the height difference between the core material and the frame, after the entire back adhesive is applied, the double-sided adhesive at the height difference point will bubble. When heated, the bubbling will affect the heat insulation adhesion. Furthermore, with the core material recessed within the U-shaped frame, after back adhesive is applied, only the double-sided adhesive on the frame surface has an adhesive effect, while the double-sided adhesive in the core material area fails and cannot contact the battery pack. Summary of the Invention

[0003] To address the shortcomings described in the prior art, the present invention provides a method for preparing an aerogel thermal insulation pad with the core material flush with one side of the U-shaped frame.

[0004] The technical solution adopted in this invention is as follows:

[0005] A method for preparing an aerogel thermal insulation pad with a core material flush with one side of a U-shaped frame, comprising the following steps:

[0006] Install the convex and concave molds onto the vacuum hot press;

[0007] The convex and concave mold includes an upper mold and a lower mold. The end face of the upper mold facing the lower mold is provided with at least one groove, and the end face of the lower mold facing the upper mold is provided with at least one boss. The groove and the boss correspond one-to-one to form the core material extrusion area. The width of the groove is less than the width of the U-shaped frame, and the length of the groove is less than the length of the U-shaped frame. The upper and lower molds are mainly used to extrude the core material and the U-shaped frame. The groove and boss structure ensures that the end face of the hot-pressed concave core material located on the groove side is flush with the U-shaped frame.

[0008] Fabric on a fabric board;

[0009] First, place the sealing film in the fabric area of ​​the fabric board, then place at least one loop frame on the lower sealing film. Place the aerogel core material in the hole in the center of the loop frame, and then place the sealing film on top. The upper and lower sealing films can be shared by each loop frame, or each loop frame can use the upper and lower sealing films independently.

[0010] Place the fabric plate after the fabric is laid into the lower mold, and make sure that the core material extrusion area corresponds to the aerogel core material.

[0011] Vacuum hot press is used for vacuum hot pressing. During the hot pressing process, the upper mold moves towards the lower mold, causing the aerogel core material to be squeezed into the groove; the end of the aerogel core material facing the groove is squeezed only into the groove.

[0012] After hot pressing, the fabric plate is removed and cooled. After cooling, the heat insulation pad product set with the aerogel core material flush with one side of the U-shaped frame is obtained.

[0013] The thermal insulation pad product group is divided into independent aerogel thermal insulation pads, and each aerogel thermal insulation pad has a structure in which the aerogel core material is flush with one side of the U-shaped frame.

[0014] In a preferred embodiment of the present invention, the lower and upper encapsulation films are integral structures. Multiple U-shaped frames are spaced apart on the lower encapsulation film, and an aerogel core material is placed within each U-shaped frame. Each U-shaped frame and each aerogel core material shares the upper and lower encapsulation films. Multiple aerogel thermal insulation pads can be fabricated simultaneously using the same upper and lower encapsulation films.

[0015] As a preferred embodiment of the present invention, for products that share the upper and lower sealing films, the heat insulation pad product group obtained after hot pressing needs to be cut into independent aerogel heat insulation pads.

[0016] In a preferred embodiment of the present invention, multiple lower encapsulation films are placed at intervals on a fabric plate, each lower encapsulation film has a U-shaped frame placed on it, and each U-shaped frame has an aerogel core material placed on it. The upper encapsulation film corresponds one-to-one with the lower encapsulation film. That is, multiple independent aerogel heat insulation pads can be fabricated simultaneously on the fabric plate.

[0017] As a preferred embodiment of the present invention, the height of the boss = thickness of the U-shaped frame - thickness of the core material + depth of the groove.

[0018] As a preferred embodiment of the present invention, the corners of the groove and the corners of the boss are both chamfered to avoid puncturing the membrane material.

[0019] This invention achieves a flush alignment between one end face of the aerogel core material and one end face of the U-shaped frame during vacuum hot pressing using upper and lower molds with a concave-convex mating structure in the preparation of the aerogel heat insulation pad. This changes the existing structure where both sides of the aerogel core material are recessed within the U-shaped frame. The aerogel heat insulation pad produced by this invention has a core material end face flush with one side of the U-shaped frame, which not only satisfies the design requirements for the thickness of the core material and the U-shaped frame in the heat insulation pad's recessed U-shaped frame structure, but also enhances the effective contact area between the flush-plane backing adhesive and the battery pack, increasing the adhesion between the heat insulation pad and the battery pack. Furthermore, this invention allows for the production of multiple pads at once, improving manufacturing efficiency and reducing the risk of double-sided adhesive bubbling. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the structure of the concave and convex mold of the present invention.

[0022] Figure 2 This is a schematic diagram of the structure of the mold of the present invention.

[0023] Figure 3 This is a schematic diagram of the structure of the aerogel heat insulation pad of the present invention.

[0024] Figure 4 for Figure 3 A magnified view of part A in the middle. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] Example:

[0027] A method for preparing an aerogel thermal insulation pad with a core material flush with one side of a U-shaped frame, comprising the following steps:

[0028] Install the convex and concave molds onto the vacuum hot press;

[0029] The convex and concave mold includes an upper mold 1 and a lower mold 2, such as Figure 1 As shown, the upper mold 1 has at least one groove 3 on its end face facing the lower mold, and the lower mold 2 has at least one boss 4 on its end face facing the upper mold. The groove and the boss correspond one-to-one to form the core material extrusion area. The width of the groove is less than the width of the U-shaped frame, and the length of the groove is less than the length of the U-shaped frame. The height of the boss is equal to the thickness of the U-shaped frame - the thickness of the core material + the depth of the groove.

[0030] The main components of the extrusion core material and the U-shaped frame are the upper and lower dies. The groove and boss structure ensures that the end face of the hot-pressed and recessed core material located on the groove side is flush with the U-shaped frame. To prevent the film material from being crushed during hot pressing, the corners of the groove and the boss are beveled.

[0031] Furthermore, for ease of installation, both the upper and lower molds are provided with fixing holes 9. This embodiment only demonstrates the upper mold as an example. Figure 2 As shown.

[0032] Fabric on a fabric board;

[0033] First, place the sealing film 5 in the fabric area of ​​the fabric board, then place at least one loop frame 6 on the lower sealing film 5, place the aerogel core material 7 in the center hole of the loop frame, and then place the sealing film 8 on top; the upper and lower sealing films can be shared by each loop frame, or each loop frame can use the upper and lower sealing films independently.

[0034] When using a shared upper and lower encapsulation film, the lower and upper encapsulation films are a single sheet structure. Multiple loop-shaped frames are placed at intervals on the lower encapsulation film, and an aerogel core material is placed in each loop-shaped frame. Each loop-shaped frame and each aerogel core material shares the upper and lower encapsulation films. Multiple aerogel thermal insulation pads can be fabricated simultaneously using the same upper and lower encapsulation films.

[0035] When using upper and lower encapsulation films individually, multiple lower encapsulation films are placed at intervals on the fabric plate. Each lower encapsulation film has a U-shaped frame, and each U-shaped frame has an aerogel core material. The upper and lower encapsulation films correspond one-to-one, meaning that multiple independent aerogel heat insulation pads can be fabricated on the fabric plate at the same time.

[0036] Place the fabric plate after the fabric is laid into the lower mold, and make sure that the core material extrusion area corresponds to the aerogel core material.

[0037] Vacuum hot press is used for vacuum hot pressing. During the hot pressing process, the upper mold moves towards the lower mold, causing the aerogel core material to be squeezed into the groove; the end of the aerogel core material facing the groove is squeezed only into the groove.

[0038] After hot pressing, the fabric plate is removed and cooled. After cooling, the heat insulation pad product set with the aerogel core material flush with one side of the U-shaped frame is obtained.

[0039] The thermal insulation pad product group is divided into individual aerogel thermal insulation pads. Each aerogel thermal insulation pad has a structure in which the aerogel core material is flush with one side of the U-shaped frame, such as... Figure 3 and 4 As shown.

[0040] For products that share the same upper and lower sealing films, the heat insulation pad product group obtained after hot pressing needs to be cut into independent aerogel heat insulation pads.

[0041] For products that use only the top and bottom sealing films, simply remove them separately.

[0042] In this embodiment, the U-shaped frame can be any of a rubber frame, a PC frame, or a foam U-shaped frame, and the aerogel core material can also be any of ceramic aerogel, pre-oxidized fiber aerogel, or glass fiber aerogel. The upper and lower encapsulation films used are PET films or PI films, etc., and the material of the encapsulation film is not limited to the types given.

[0043] In this specification, the terms "an embodiment," "example," "specific example," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0044] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for preparing an aerogel thermal insulation pad with a core material flush with one side of a U-shaped frame, characterized in that, The steps are as follows: Install the convex and concave molds onto the vacuum hot press; The convex and concave mold includes an upper mold and a lower mold. The end face of the upper mold facing the lower mold is provided with at least one groove, and the end face of the lower mold facing the upper mold is provided with at least one boss. The groove and the boss correspond one-to-one to form the core material extrusion area. The width of the groove is less than the width of the U-shaped frame, and the length of the groove is less than the length of the U-shaped frame. Fabric on a fabric board; First, place the encapsulation film in the fabric area of ​​the fabric board, then place at least one U-shaped frame on the lower encapsulation film, place the aerogel core material in the hole in the center of the U-shaped frame, and then place the encapsulation film on top. Place the fabric plate after the fabric is laid into the lower mold, and make sure that the core material extrusion area corresponds to the aerogel core material. Vacuum hot press is used to apply vacuum hot press. During the hot press process, the upper mold moves towards the lower mold, causing the aerogel core material to be squeezed into the groove. After hot pressing, the fabric plate is removed and cooled. After cooling, the heat insulation pad product set with the aerogel core material flush with one side of the U-shaped frame is obtained. The thermal insulation pad product group is divided into independent aerogel thermal insulation pads, and each aerogel thermal insulation pad has a structure in which the aerogel core material is flush with one side of the U-shaped frame.

2. The method for preparing a single-sided flush aerogel thermal insulation pad with core material and U-shaped frame according to claim 1, characterized in that: The lower and upper encapsulation films are integral structures. Multiple loop-shaped frames are placed at intervals on the lower encapsulation film, and an aerogel core material is placed in each loop-shaped frame. Each loop-shaped frame and each aerogel core material shares the upper and lower encapsulation films.

3. The method for preparing a single-sided flush aerogel thermal insulation pad with core material and U-shaped frame according to claim 2, characterized in that: The heat insulation pad product group obtained after hot pressing needs to be cut into independent aerogel heat insulation pads.

4. The method for preparing a single-sided flush aerogel thermal insulation pad with core material and U-shaped frame according to claim 1, characterized in that: Multiple lower encapsulation films are placed at intervals on the fabric plate. A herringbone frame is placed on each lower encapsulation film, and an aerogel core material is placed on each herringbone frame. The upper encapsulation film corresponds one-to-one with the lower encapsulation film.

5. The method for preparing a single-sided flush aerogel thermal insulation pad with core material and U-shaped frame according to claim 2, 3, or 4, characterized in that: The height of the boss = thickness of the U-shaped frame - thickness of the core material + depth of the groove.

6. The method for preparing a single-sided flush aerogel thermal insulation pad with core material and U-shaped frame according to claim 5, characterized in that: The corners of the grooves and the corners of the bosses are all chamfered.

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