Thermal escape flue gas management

Abstract

The invention relates to an assembly for a vehicle, which protects a passenger compartment from contamination of gases released from a battery module in the event of heat dissipation. The released gas propagates into a hollow element of the vehicle that provides a channel that is blocked at a location by the expanded cured adhesive material, thereby providing a barrier to the gas.

Description

Technical Field

[0001] The present invention claims priority from European patent application No. 22 181 117.7 filed on June 24, 2022.

[0002] The present invention relates to an assembly for a vehicle that protects the passenger compartment from contamination by gases released from a battery module in the event of thermal runaway. The released gases propagate into a hollow element of the vehicle that provides a channel that is blocked at a certain location by an expanded, cured adhesive material, thereby providing a barrier to the gas. Background Art

[0003] Rechargeable battery cells of vehicles are susceptible to elevated temperatures because heated cell components can overcome chemical activation energy and decompose in an exothermic chemical reaction. In the worst case, if heated to a critical temperature, the undesirable self-heating rate of the cell becomes greater than the heat dissipation rate, and the cell will turn into so-called "thermal runaway". In the case of rechargeable lithium-ion cells with high energy density, thermal runaway is a rapid, violent, self-accelerating chemical reaction of electrodes and electrolytes that releases large amounts of heat and gas. The gas may contain, for example, H2, CO, CH4, C2H4, C2H6, C3H8, HF, POF3, PF5, making it flammable and toxic (J. Sun et al., Nano Energy 27 (2016) 313-319). The battery pack is typically assembled inside the available space in the luggage compartment of the vehicle. Thus, the only barrier between the car occupants and the lithium-ion cells is the housing of the battery pack. The housing must protect the occupants from any gas or heat emissions from the lithium-ion cells (AW Globukov et al., RSC Adv. 2018, 8, 40172-40186).

[0004] Various safety features have been developed for high energy density lithium-ion batteries to improve safety by focusing on avoiding and early detection of thermal runaway. These safety features include cathode material design, anode modification, modification of traditional polyolefin membranes, separators with high thermal stability, functionalized separators, modified electrolytes, alternative lithium salts, functional additives, non-flammable electrolyte systems, etc. (J. Duan et al., Electrochemical Energy Reviews (2020) 3: 1-42; X. Feng et al., Joule 4, 743-770, April 15, 2020).

[0005] US2010 0136404A1 relates to a battery pack, which includes one or more thermal barrier elements that divide the cells in the battery pack into groups of cells. The thermal barrier elements that separate the cells into groups prevent a thermal runaway event triggered in one group of cells from propagating to cells in adjacent groups of cells.

[0006] US2013 0273400A1 discloses a battery pack system, which includes at least one cell carrier assembly configured to provide current during use. The battery pack system also includes a battery pack enclosure for accommodating at least one cell carrier assembly. The battery pack enclosure has at least one wall having at least one channel, the at least one channel being sized to receive an edge of the cell carrier assembly to position the cell carrier assembly at a position within the battery pack enclosure and provide a thermal path during use.

[0007] WO 2015 179625A1 provides a lithium-ion battery comprising a material that provides a favorable endothermic function that is beneficial to the safety and stability of the battery. The endothermic material may include a ceramic matrix combined with an endothermic material that generates an inorganic gas. If the temperature of the lithium-ion battery rises above a predetermined level, the endothermic material is used to provide one or more functions to prevent and / or minimize the possibility of thermal runaway, for example, thermal insulation (especially at high temperatures); (ii) energy absorption; (iii) exhaust all or part of the gas generated by the endothermic reaction associated with the endothermic material, (iv) increase the total pressure within the battery structure; (v) remove the absorbed heat from the battery system by exhausting the gas generated during the endothermic reaction associated with the endothermic material, and / or (vi) dilute the toxic gas (if present) and expel it safely from the battery system.

[0008] WO 2016 141467A1 provides an apparatus, method and system for thermal runaway and exhaust management of high-power batteries. The battery module has a plurality of carriers containing battery cells, which are stacked on top of each other to form a battery cell stack having a front end and a rear end. A pipeline extends through the battery cell stack between the front end and the rear end for collecting escaped gases from the battery cells. A self-closing one-way pressure relief valve is located in the pipeline toward the rear end of the battery cell stack. The pressure relief valve is connected to a pipeline system for transporting the gas to a remote location where the gas can be safely released and dispersed.

[0009] US2017 0025720A1 relates to an energy storage unit, in particular a battery module, having a plurality of galvanic cells, in particular battery cells, wherein the galvanic cells each have a first outer side with a first electrode and a second outer side with a second electrode, and the galvanic cells are electrically interconnected with one another via the electrodes by means of the outer sides through the juxtaposition of the galvanic cells. The invention therefore generally relates to the interconnection of galvanic cells, in particular battery cells, to form a multi-cell energy storage.

[0010] US2017 0155155A1 relates to a battery electrode assembly comprising a current collector having a conductive barrier region, which has a conductive state that allows conductivity through the conductive barrier region and a safe state that reduces conductivity through the conductive barrier region.

[0011] US2019 292427A1 relates to a structural adhesive formulation which is heat-activatable at a heat activation temperature; can melt without heat activation at an application temperature above its melting point and below the heat activation temperature; and is solid at ambient temperature; wherein upon heat activation, the structural adhesive formulation is capable of expanding with a volume expansion of up to about 250 volume %; wherein the heat-activatable structural adhesive formulation comprises: (a) an epoxy resin component; (b) an adhesion promoter component; (c) a cross-linking component; (d) a blow molding component; (e) optionally, an impact modifier component; (f) optionally, a thixotropic filler component; and (g) optionally, a non-thixotropic filler component.

[0012] US20210066683A1 relates to a method for preventing or minimizing the occurrence of thermal runaway events in a battery module of an electric vehicle. The method places a gas barrier between the wall of each battery cell and the ventilation space so that gas escaping from one battery cell does not impact another battery cell.

[0013] US2021 0351440A1 provides a wound battery cell and a preparation method thereof, a battery, and an electronic product. It is said that the provided features help reduce the safety risks caused by lithium plating during the fast charging process of lithium-ion batteries.

[0014] US2021 0376405A1 relates to a composite thermal barrier material for use in battery packs of electric and hybrid vehicles. The composite material comprises a porous core layer, a pair of flame retardant layers arranged on either side of the porous core layer, and at least one radiation barrier layer arranged between one of the pair of flame retardant layers and the porous core layer.

[0015] US2022 0069377A1 relates to a high-voltage battery module and a battery pack in which a thermal barrier is installed, and more specifically, to a battery module comprising a cell assembly stacked with a plurality of secondary battery cells; a shell accommodating the cell assembly, in which the thermal barrier is placed, wherein the thermal barrier includes a heat-resistant layer to prevent heat or flame from propagating from the secondary battery cell to adjacent secondary battery cells.

[0016] US2022 0109131A1 discloses a method comprising selectively applying a light-curing adhesive to a recess in a first side of a carrier layer and inserting a battery cell into the corresponding recess. The method also includes exposing the first side of the carrier layer to light to at least partially cure the light-curing adhesive with the carrier layer in a first orientation, moving the carrier layer to a second orientation, and exposing the second opposite side of the carrier layer to light to fully cure the light-curing adhesive. The recess may include a sidewall having crush points spaced apart along the sidewall and a bottom having an opening between a pair of crush points, wherein the adhesive is not arranged between the pair of crush points.

[0017] US2022 013758A1 relates to a vehicle battery pack, comprising: a housing having an internal space for accommodating battery cells therein, an inlet for introducing air into the internal space of the housing, an outlet for exhausting air from the internal space of the housing, and an expandable foam member arranged in at least a portion of each of the inlet and the outlet.

[0018] US2022 0158291A1 relates to a battery module comprising an array of electrochemical cells and a frame configured to support the cells within the battery module, the frame surrounding the array in a manner covering the cell side walls of each cell and exposing the first cell end and the second cell end of each cell.

[0019] US2022 200079A1 details an exemplary traction battery pack ventilation system for use in an electrified vehicle. An exemplary traction battery pack system may include a ventilation system having one or more ventilation ducts for discharging battery ventilation byproducts from the battery pack. The ventilation duct may include a thermal barrier configured to block heat emitted by battery ventilation byproducts during a battery cell ventilation event. In some embodiments, the thermal barrier includes a thermal barrier coating. In other embodiments, the thermal barrier includes both a thermal barrier coating and a thermal barrier layer. In some other embodiments, a second thermal barrier may be applied to a vehicle component located near the battery pack for improving thermal barrier properties.

[0020] EP 3 985 784 A1 relates to a battery for an aircraft. The battery may include a battery housing having a housing wall forming an internal volume, a plurality of battery cells arranged in the internal volume, and a functional layer at the housing wall and the battery housing arranged between the plurality of battery cells. The functional layer may include an intumescent material, which, in the event of a rupture of the battery housing, is suitable for ensuring that a flame is contained within the internal volume and for mitigating uncontrolled discharge of heat and gases from the internal volume due to a rupture of the battery housing.

[0021] Although the safety of high energy density batteries has improved over the years, making thermal runaway less likely, it remains a considerable risk that cannot be ruled out with absolute certainty.

[0022] Therefore, a solution is needed to deal with thermal runaway as soon as it occurs. In particular, a method is needed to deal with the hazardous gases released during thermal runaway in an environmentally friendly manner and without causing harm to the occupants of the vehicle. Summary of the invention

[0023] The object of the present invention is to provide an improved assembly for a vehicle which is able to capture the hazardous gases released during thermal runaway in an environmentally friendly manner and without causing harm to the occupants of the vehicle.

[0024] This object has been achieved by the subject matter of the patent claims.

[0025] It has been surprisingly discovered that the gases released during thermal runaway can be supplied to the hollow structure of the vehicle. The gases can be trapped within the hollow structure and / or directed to a location in the vehicle where they can cool without entering the passenger compartment (passenger cabin) or otherwise causing harm to the occupants of the vehicle.

[0026] Further, it has surprisingly been found that an expandable curable adhesive material can be used within a hollow structure of a vehicle, which, when expanded and cured, blocks specific passages within the hollow structure by providing a barrier to gas. Thus, positioning the adhesive material at the correct location within the hollow structure enables the gas to be directed along a specific route within the free (unblocked) passages of the hollow structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figures 1 to 3 A preferred embodiment of the assembly according to the invention is schematically shown. Figure 4 The experimental setup is shown. DETAILED DESCRIPTION

[0028] A first aspect of the present invention relates to an assembly for a vehicle, the assembly comprising

[0029] - a battery module having a vent port through which gases are released from the battery module in the event of thermal runaway;

[0030] a hollow member defining an optionally branched channel connected to the exhaust port in a gas-permeable manner so that, in the event of thermal runaway, gases released from the battery module through the exhaust port propagate into the channel; and

[0031] - a barrier element attached to at least a portion of the inner surface of the wall of the hollow member at the location of the passage, and the barrier element comprises or consists essentially of an expandable, curable adhesive material, the expandable, curable adhesive material being configured such that after the adhesive material expands and cures, the barrier element blocks the passage at that location and provides a barrier to gas.

[0032] Thus, the expandable curable adhesive material and the barrier element are configured to block the passageway and provide a barrier to gas at that location when the adhesive material is activated to expand and cure.

[0033] Activating the adhesive material to expand and solidify can occur as a precaution during the manufacturing operations of the vehicle (permanent blocking). According to a preferred embodiment of the present invention, the expandable curable adhesive material is then configured to expand and solidify during the manufacturing operations of the vehicle (for example, in a body-in-white oven and / or during an electrophoretic coating operation), so that the manufactured vehicle includes the material in an expanded and solidified state. As a precaution, regardless of whether thermal runaway occurs, in the manufactured vehicle, the blocking element permanently blocks the channel at this position and, if there is gas, provides a permanent barrier to the gas. According to these embodiments, the expandable curable adhesive material is configured to expand and solidify during the manufacturing operations of the vehicle, so that the vehicle includes the adhesive material in its expanded and solidified state after its manufacture, and the blocking element permanently blocks the channel at this position and provides a barrier to the gas.

[0034] Alternatively, activation of the adhesive material to expand and solidify may occur during operation of the manufactured vehicle (blockage caused by thermal runaway). According to a preferred embodiment of the present invention, the expandable curable adhesive material is then configured to expand and solidify when in contact with gas in the event of thermal runaway during operation of the vehicle, so that the manufactured vehicle initially includes a material in an expandable and curable state. In the absence of thermal runaway, in the manufactured vehicle under normal operation, the blocking element does not block the channel at this position and does not provide a barrier to gas. Only in the case of thermal runaway, when gas is released from the battery module and propagates through the channel so that it contacts the blocking element and heats the expandable curable adhesive material, the adhesive material is activated to expand and solidify so that it blocks the channel at this position and provides a barrier to gas. According to these embodiments, the expandable, curable binding material is configured to expand and cure upon contact with a gas (and heat transfer) during thermal runaway, such that the vehicle, after its manufacture, initially includes the material in its expandable and curable state, which is converted to its expanded and cured state in the event of thermal runaway.

[0035] The assembly according to the invention can therefore exist in different situations (states, conditions):

[0036] - in case (i) (normal operation), there is normal operation of the battery module without thermal runaway;

[0037] - In case (ii) (non-routine operation), there is non-routine operation of the battery module, ie, thermal runaway in which gas is released from the battery module through the exhaust port so that the gas propagates into the channel.

[0038] In both cases, the bonding material may initially be present (a) in its expanded and cured state (permanent blocking), or (b) in its expandable and curable state (blocking caused by thermal runaway).

[0039] When the adhesive material is initially already (a) in its expanded and cured state (permanent blocking),

[0040] - in normal operation (case (i)), the blocking element permanently blocks the passage at that location and provides a permanent blockage; and

[0041] - In the case of non-routine operation (case (ii)), in the case of thermal runaway, the gases released from the battery module propagate into the channel, but cannot pass through the barrier element, because the adhesive material is already present in its expanded and cured state, so that it permanently blocks the channel. In these cases, thermal runaway does not change the state of the adhesive material, because it has already been expanded and cured previously, i.e. during the manufacturing operation of the vehicle.

[0042] When the bonding material is initially (b) present in its expandable, curable state (blocking caused by thermal runaway),

[0043] - in normal operation (case (i)), the obstructing element does not block the passage at this position and does not provide obstruction; and

[0044] - In the case of non-conventional operation (case (ii)), in the case of thermal runaway, the gas released from the battery module propagates into the channel and causes expansion and solidification of the adhesive material upon contact. Initially, when the propagating gas has not yet reached the expandable curable material and has not yet heated the expandable curable material to its activation temperature (i.e., expansion activation temperature and curing activation temperature), the adhesive material is still expandable and curable, i.e., has not yet undergone expansion or solidification, and does not block the channel at this position, so that it does not provide a barrier to gas. However, after a certain time, after the propagating gas has reached the expandable curable material and has heated the expandable curable material to its activation temperature (i.e., expansion activation temperature and curing activation temperature), the expansion and solidification of the adhesive material are caused by heat transfer. The originally expandable curable material is then transformed into an expanded and solidified material and blocks the channel at this position, so that it provides a barrier to gas. The gas cannot pass through the barrier element because the adhesive material then exists in its expanded and solidified state, causing it to block the channel. In these cases, the thermal runaway changes the state of the bonding material; although it initially exists in its expandable, curable state (i.e., has not been previously expanded and cured during the vehicle manufacturing operation), it is activated by the thermal runaway and converted to its expanded, cured state.

[0045] It has been found that there are advantages to expand and solidify the adhesive material (permanent blockage) during the manufacturing operation of the vehicle. The permanent blockage thus obtained does not require any heat transfer from the gas to the adhesive material. When the gas reaches the position of the passage, the blockage is already in place. Therefore, the blockage hinders any gas from passing through from the very beginning of the heat runaway. On the contrary, it takes a period of time to cause the expansion and solidification of the adhesive material in the case of heat runaway (blockage caused by heat runaway) until the activation temperature of the expandable curable adhesive material (i.e., the expansion activation temperature and the curing activation temperature) has been reached. During this period, the first part of the gas can pass along the barrier element because the barrier element gradually forms its barrier effect with a certain delay.

[0046] For purposes of this specification, "thermal runaway" is any event that causes heated gases to be inadvertently generated and released from a battery module due to a failure of the battery module.

[0047] The battery module has a vent port for releasing gas from the battery module in the event of thermal runaway. Therefore, the vent port can exist in different situations (states, conditions):

[0048] - In case (i) (normal operation), there is normal operation of the battery module without thermal runaway. In these cases, no gas is released from the battery module;

[0049] - In case (ii) (non-routine operation), there is non-routine operation of the battery module, ie, thermal runaway, and gas is released from the battery module through the exhaust port, causing the gas to propagate into the channel.

[0050] Similarly, all other elements of the assembly according to the invention may be present in different instances (i) and (ii), which instances are not individualized for each element below.

[0051] The exhaust port is preferably an integrated part of the battery module and is located at a position to collect heated gases in the event of thermal runaway so that the gases can be released from the battery module in a controlled manner. The exhaust port can be equipped with a vent so that the heated gases need to be at a predetermined pressure within the battery module before being released through the exhaust port.

[0052] The hollow member of the vehicle has a wall defining a channel, which can be optionally branched. For example, the hollow member can be part of a frame of the vehicle, wherein the wall of the frame defines a channel through which the gas can propagate. The channel is connected to the exhaust port in a gas-permeable manner so that in the case of thermal runaway, the gas released from the battery module through the exhaust port propagates into the channel. Suitable connectors are known to those skilled in the art and include, but are not limited to, fittings, pipe joints, etc. Typically, the channel is connected to the exhaust port in a secure manner so that no gas can escape into the environment. Therefore, the entire amount of gas released from the battery module through the exhaust port typically enters the channel. The gas thus released then propagates through the channel due to diffusion or by active transmission, for example, by means of a vent.

[0053] The barrier element comprises or consists essentially of an expandable curable adhesive material. In addition to the adhesive material, the barrier element may include a carrier. The adhesive material exists in two different states. In its initial state, the adhesive material is in its green state and is expandable and curable when activated by a suitable stimulus, preferably an elevated temperature. Alternative stimuli are also contemplated, such as actinic radiation, moisture, etc. In its activated state, the material is cured (thermosetting, hardening) and expanded (e.g., foamed).

[0054] Existing in the initial state and can be activated to provide the expandable curable material of the solidified state of expansion is mainly known to the technician and is commercially available.When the expandable curable adhesive material is heated, it expands, crosslinks and is structurally bonded to adjacent surfaces.The example of preferred preparation is an epoxy material, which can be commercially available from the L&L Products company in Romeo, Michigan, and the name includes L-5204, L-5207, L-5214, L-5234, L-5235, L-5236, L-5237, L-5244, L-5505, L-5510, L-5520, L-5540, L-5573 or its combination.This material can show the characteristics including relatively high strength and rigidity, promotes adhesion, rigidity, and gives other valuable physical and chemical characteristics and characteristics.

[0055] Preferably, the bonding material provides good adhesion to metals when activated, with good corrosion resistance. Furthermore, the bonding material is preferably compatible with the electrophoretic coating technique, i.e. it is not washed away when exposed to the washing and rinsing steps typically applied during the electrophoretic coating technique. Furthermore, the expansion activation temperature and the curing activation temperature of the bonding material are preferably adjusted such that the expansion and curing of the bonding material are activated at this temperature in the electrophoretic coating oven.

[0056] The barrier element is attached to at least a portion of the inner surface of the wall of the hollow member at a location of the passage. The barrier element can be attached to the surface by the inherent adhesion of the adhesive material itself. Alternatively, the barrier element can be equipped with a device for attaching it to the surface. Suitable devices include, but are not limited to, mechanical fasteners, pressure-sensitive adhesives, etc.

[0057] The position at which the barrier element in the channel is attached to the inner surface of the wall of the hollow element can be freely selected. It is also conceivable that the channel includes more than one barrier element at different positions. Then, more than one barrier element can have the same design, composition and size or have different designs, compositions and / or sizes independently of each other. The position at which the barrier element in the channel is attached to the inner surface of the wall of the hollow element is preferably selected to be near the branch point of the channel, i.e. the position at which the channel is divided into the first branch and the second branch. Preferably, the barrier element is attached to the inner surface of the wall of the hollow element at the position of the branch of the channel, and the channel will be connected to the passenger compartment of the vehicle in a gas-permeable manner in other cases. Therefore, when the barrier element blocks the branch of the channel at such a position after expansion (i.e., volume expansion, foaming) and curing (i.e., hardening, cross-linking), it provides a barrier to the gas and the gas cannot be further propagated through the branch of the channel, thereby preventing the passenger compartment from being polluted by the gas passing through the branch of the channel.

[0058] Thus, the present invention allows gases released from the battery module in the event of thermal runaway to be directed to a controlled location of the vehicle, typically towards the rear of the vehicle, so that no gases can enter the passenger compartment.

[0059] In a preferred embodiment of the assembly according to the invention, the adhesive material before expansion and curing is dry and non-sticky to the touch at 23° C. For the purposes of this specification, an adhesive material is considered to be non-sticky to the touch if no force exceeding 2 N is required to pull out a 25 mm diameter stainless steel plate applied to the surface of the adhesive material.

[0060] In a preferred embodiment of the assembly according to the present invention, the volume of the adhesive material after expansion and curing is at least 50% by volume, preferably at least 100% by volume, more preferably at least 150% by volume greater than its volume before expansion and curing. In a preferred embodiment, the volume expansion is in the range of 150 to 250% by volume compared to the volume before expansion and curing. In other preferred embodiments of the assembly according to the present invention, the volume of the adhesive material after expansion and curing is at least 250% by volume, preferably at least 500% by volume, more preferably at least 1000% by volume greater than its volume before expansion and curing. In a preferred embodiment, the volume expansion is in the range of 250 to 2500% by volume compared to the volume before expansion and curing.

[0061] In a preferred embodiment of the assembly according to the invention, the bonding material after expansion and curing (ie the expanded cured bonding material) forms a layer or sheet having a thickness of at least 1 mm, preferably at least 2 mm, more preferably at least 3 mm.

[0062] In a preferred embodiment of the assembly according to the invention, the bonding material after expansion and curing (ie the expanded cured bonding material) forms a layer or sheet having a thickness of at most 6 mm, preferably at most 5 mm, more preferably at most 4 mm.

[0063] In a preferred embodiment of the assembly according to the invention, the adhesive material has an expansion activation temperature in the range of 100° C. to 200° C., preferably in the range of 140° C. to 180° C., more preferably about 160° C. In a further preferred embodiment of the assembly according to the invention, the adhesive material has an expansion activation temperature in the range of 10° C. to 30° C., so that it is expandable at room temperature.

[0064] In a preferred embodiment of the assembly according to the invention, the adhesive material has a curing activation temperature in the range of 100° C. to 200° C., preferably in the range of 140° C. to 180° C., more preferably about 160° C. In a further preferred embodiment of the assembly according to the invention, the adhesive material has a curing activation temperature in the range of 10° C. to 30° C., so that it is curable at room temperature.

[0065] When the expansion activation temperature and / or the curing activation temperature are in the range of 10° C. to 30° C., the expandable curable adhesive material is preferably based on a two-component system, which spontaneously begins to expand and cure when the two components of the two-component system are mixed with each other, for example at room temperature. Since expansion and curing require some time, the adhesive material in its expanding and curing state (open time) can then be attached to at least a portion of the inner surface of the wall of the hollow member at a position in the channel, where continued expansion and curing will block the channel until the expansion and curing have ended and the adhesive material is thermoset (cured, hardened). Alternatively, during the process of applying the adhesive material to at least a portion of the inner surface of the wall of the hollow member at a position in the channel, the two components can be mixed with each other, for example by means of an applicator as follows: a storage cartridge equipped with two separate chambers for the two components of the two-component system, and having an application outlet, at which the two components are mixed with each other just before they leave the applicator.

[0066] The expandable curable adhesive material can be provided as a film or layer. The thickness of the film or layer is not particularly limited. Those skilled in the art recognize that in order to block the passage after the expansion and curing adhesive material, the amount of the expandable curable adhesive material that needs to be positioned in the passage depends on the size of the passage, especially its cross section and diameter, and the volume expansion of the adhesive material. The degree of volume expansion depends on the type and amount of the blowing agent contained in the adhesive material, and can be determined by routine testing.

[0067] Preferably, the adhesive material comprises:

[0068] (a) one or more monomers, prepolymers or polymers comprising reactive functional groups capable of undergoing a curing reaction;

[0069] (b) a curing agent for (a), which is generally capable of undergoing a curing reaction with or inducing a curing reaction of one or more reactive functional groups of the monomers, prepolymers or polymers (a);

[0070] (c) optionally, a curing agent activator;

[0071] (d) foaming agent;

[0072] (e) optionally, a blowing agent activator;

[0073] (f) optionally, one or more additional polymers; preferably, wherein the one or more additional polymers do not comprise the reactive functional groups of the one or more monomers, prepolymers or polymers (a);

[0074] (g) optionally, a toughening agent;

[0075] (h) optionally, one or more fillers; and

[0076] (i) Optionally, one or more flame retardants and / or smoke suppressants.

[0077] The one or more monomers, prepolymers or polymers comprising reactive functional groups capable of undergoing a curing reaction may be based on different chemistries, preferably epoxy chemistry, polyurethane chemistry, acrylate chemistry, or mixtures thereof.

[0078] The curing agent capable of undergoing a curing reaction with or causing a curing reaction of the reactive functional groups of one or more monomers, prepolymers or polymers (a) can similarly be based on different chemistries, preferably a curing agent for epoxy resins, polyurethane resins, acrylate resins, or mixtures thereof.

[0079] Curing agent activators may likewise be based on different chemistries, depending on the chemistry of the monomer, prepolymer or polymer (a) and the respective curing agent.

[0080] The one or more additional polymers, which preferably do not comprise said reactive functional groups of the above-mentioned one or more monomers, prepolymers or polymers (a), may likewise be based on different chemistries, depending on the chemical nature of the monomers, prepolymers or polymers (a).

[0081] Expandable curable adhesive materials based on epoxy chemistry, polyurethane chemistry, or acrylate chemistry are known to the skilled person. In this regard, reference is made to the following documents, all of which are incorporated herein by reference: US2003 0018095, US2004 0082673, US2004 0204551, US20040224108, US2005 0022929, US2005 0043420, US2007 0207284, US20070281523, US2010 0028651, US2010 0183863, US2010 0280167, US20130020832, US2015 0198051, 2015 0266518, US2015 0352930, US20150367893, US20160122539, US2016 0201708, US2019 0144718, US20190292427, US2020 0216722 and US20210380852.

[0082] The blowing agent can be a chemical blowing agent or a physical blowing agent.

[0083] Preferably, the blowing agent is a chemical blowing agent; preferably selected from the group consisting of azodicarbonamide, dinitrosopentamethylenetetramine, 4,4'-oxy-bis-(benzenesulfonylhydrazide), trihydrazino-s-triazine, and N,N'-dimethyl-N,N'-dinitrosoterephthalamide; more preferably azodicarbonamide.

[0084] It is also contemplated that the blowing agent is a physical blowing agent, such as expandable microspheres. Suitable expandable microspheres are commercially available (e.g. ).

[0085] Preferably, the foaming agent activator is zinc oxide, which may be generally contained in an amount of 1 to 10 wt % relative to the weight of the bonding material.

[0086] Preferably, the toughening agent is ethylene methacrylate copolymer.

[0087] Preferably, the toughening agent is an epoxy / elastomer adduct; preferably, wherein the epoxy is a diglycidyl ether of bisphenol (DGEB), and wherein the elastomer is selected from the group consisting of: carboxyl-terminated butadiene acrylonitrile rubber (CTBN), carboxyl-terminated polybutadiene (CTPB), hydroxyl-terminated butadiene acrylonitrile rubber (HTBN), hydroxyl-terminated polybutadiene (HTPB), amine-terminated butadiene acrylonitrile rubber (ATBN), epoxidized hydroxyl-terminated polybutadiene (EHTPB), and mixtures thereof; more preferably, wherein the epoxy is a diglycidyl ether of bisphenol A (DGBEA) or a diglycidyl ether of bisphenol F (DGBEF), and wherein the elastomer is a carboxyl-terminated butadiene acrylonitrile rubber (CTBN). Other toughening agents are known to those skilled in the art and are also contemplated.

[0088] Mixtures of two or more toughening agents are also contemplated.

[0089] Preferably, the total content of one or more toughening agents is in the range of 25±20 wt.-%, preferably 25±15 wt.-%, more preferably 25±10 wt.-%, even more preferably 25±5 wt.-%, in each case relative to the total weight of the adhesive material.

[0090] Preferably, the one or more fillers comprise or consist essentially of calcium oxide, magnesium oxide, calcium carbonate, magnesium carbonate, talc, wollastonite, bentonite, kaolin, mica, powdered quartz, fumed silica, silica aerogel, coal tar, carbon black, glass particles, textile fibers, glass fibers, aramid fibers, aramid pulp, boron fibers, carbon fibers, and mixtures thereof.

[0091] Preferably, the total content of one or more fillers is in the range of 30±25 wt.-%, preferably 30±20 wt.-%, more preferably 30±15 wt.-%, further more preferably 30±10 wt.-%, yet further more preferably 30±5 wt.-%, in each case relative to the total weight of the adhesive material.

[0092] Preferably, one or more flame retardants and / or smoke suppressants are selected from

[0093] (i) halogen-containing flame retardants and / or smoke suppressants; for example, bromine compounds, chlorine compounds or halogenated phosphates;

[0094] (ii) Inorganic flame retardants and / or smoke suppressants; for example, metal hydroxides, metal oxides, silicon-containing additives, ammonium polyphosphate, red phosphorus, expandable graphite;

[0095] (iii) organic phosphorus / nitrogen flame retardants and / or smoke suppressants; for example, aliphatic phosphates, aliphatic phosphonates, aromatic phosphonates; and

[0096] (iv) Inherent flame retardant and / or smoke suppressant systems.

[0097] For details, refer to L. Chen et al., Polym. Adv. Technol., 2010, 21, 1-26.

[0098] In a preferred embodiment, the bonding material is based on epoxy chemistry and comprises

[0099] (a) one or more polymers comprising reactive epoxy functional groups (curable epoxy resins);

[0100] (b) a curing agent for (a); preferably a latent curing agent for (a);

[0101] (c) optionally, a curing agent activator; and

[0102] (f) Optionally, one or more polymers that do not include reactive epoxy functional groups.

[0103] Preferably, the one or more polymers comprising reactive epoxy functional groups comprise or consist essentially of one or more solid epoxy resins, one or more liquid epoxy resins, one or more glycidyl (meth)acrylate copolymers, one or more glycidyl (meth)acrylate terpolymers, or mixtures thereof.

[0104] Preferably, the one or more solid epoxy resins and / or the one or more liquid epoxy resins are independently of one another diglycidyl ethers of bisphenols (DGEB), preferably diglycidyl ether of bisphenol A (DGBEA) and / or diglycidyl ether of bisphenol F (DGBEF).

[0105] Preferably, the total content of the one or more polymers comprising reactive epoxy functional groups is in the range of 30±25 wt.-%, preferably 30±20 wt.-%, more preferably 30±15 wt.-%, further more preferably 30±10 wt.-%, yet further more preferably 30±5 wt.-%, in each case relative to the total weight of the adhesive material.

[0106] Preferably, the latent curing agent is selected from the group consisting of aliphatic amines, alicyclic amines, aromatic amines, modified polyamines, unmodified polyamines, modified polyamides, unmodified polyamides, blocked amines, amidoamines, acid anhydrides, polycarboxylic acid polyesters, isocyanates, phenolic resins, phenol novolac resins, cresol novolac resins, copolymers of phenol terpenes, polyvinylphenol, bisphenol A formaldehyde copolymers, bishydroxyphenylalkanes, hydrazides, sulfones, diaminodiphenyl sulfones, or mixtures thereof; preferably guanidine; more preferably selected from the group consisting of dicyandiamide (cyanoguanidine), methylguanidine, dimethylguanidine, trimethylguanidine, tetramethylguanidine, methylisobiguanide, dimethylisobiguanide, tetramethylisobiguanide, hexamethylisobiguanide, heptamethylisobiguanide, and mixtures thereof; further more preferably dicyandiamide.

[0107] Preferably, the curing agent activator is selected from the group consisting of modified urea (substituted urea) or unmodified urea, imidazoles and mixtures thereof; preferably methylene diphenyl bisurea.

[0108] Preferably, the one or more polymers that do not include reactive epoxy functional groups include or consist essentially of one or more ethylene (meth)acrylate copolymers, one or more ethylene vinyl acetate copolymers, and mixtures thereof.

[0109] Preferably, the total content of the one or more polymers not comprising reactive epoxy functional groups is in the range of 5.0±4.5% by weight relative to the total weight of the bonding material.

[0110] In other preferred embodiments, the adhesive material is based on acrylate chemistry and comprises:

[0111] (a) one or more monomers or prepolymers comprising ethylenically unsaturated functional groups, typically acrylic groups, or polyolefin-based copolymers;

[0112] (b) a curing agent for use in (a);

[0113] (c) optionally, a curing agent activator;

[0114] (d) blowing agents; and

[0115] (f) Optionally, one or more polymers that do not include ethylenically unsaturated functional groups.

[0116] Suitable monomers or prepolymers comprising ethylenically unsaturated functional groups are known to the skilled person and include, but are not limited to, (meth)acrylic acid, (meth)acrylic acid C 1-6 -alkyl ester, (meth) acrylate hydroxy C 1-6 -alkyl esters, cycloalkyl (meth)acrylates, and mixtures thereof.

[0117] Multifunctional monomers such as dipentaerythritol pentaacrylate can promote crosslinking.

[0118] Curing agents chemically compatible with acrylates are known to those skilled in the art, and include, but are not limited to, curing agents such as N,N-dimethyl-p-toluidine (DMPT), N-(2-hydroxyethyl)-N-methyl-p-toluidine (MHPT), N-methyl-N-(2-hydroxypropyl)-p-toluidine (2HPMT), and N-ethyl-N-(2-hydroxyethyl)-p-toluidine (EHPT); more preferably N-methyl-p-toluidine derivatives, N-(2-hydroxyethyl)-N-methyl-p-toluidine, N-ethyl-N-(2-hydroxyethyl)-p-toluidine, or any combination thereof.

[0119] A polymerization initiator, such as a peroxide, may cause curing.

[0120] In other preferred embodiments, the adhesive material is based on polyurethane chemistry and comprises:

[0121] (a) one or more monomers, prepolymers or polymers comprising isocyanate and / or hydroxyl functional groups;

[0122] (b) a curing agent for use in (a);

[0123] (c) optionally, a curing agent activator;

[0124] (d) a blowing agent; and

[0125] (f) Optionally, one or more polymers that do not include isocyanate and / or hydroxyl functional groups.

[0126] Suitable monomers, prepolymers or polymers comprising isocyanate and / or hydroxyl functional groups are known to the skilled person.

[0127] Curing agents which are compatible with polyurethane chemistry are known to the skilled person.

[0128] The adhesive material according to the present invention may contain additional additives and auxiliary substances conventionally used in adhesive materials for vehicles, such as impact modifiers, tackifiers, thermoplastics, phenoxy resins, reactive diluents, and the like.

[0129] In a particularly preferred embodiment, the adhesive material according to the invention comprises the following components in the following contents (embodiments A1 to A6):

[0130] A1 A2 A3 A4 A5 A6 Curable polymer 45.0±40.0 45.0±35.0 45.0±30.0 45.0±25.0 45.0±20.0 45.0±15.0 Curing agent 2.5±2.4 2.5±2.3 2.5±2.2 2.5±2.1 2.5±2.0 2.5±1.9 Foaming agent 2.5±2.4 2.5±2.3 2.5±2.2 2.5±2.1 2.5±2.0 2.5±1.9 Optionally, a toughening agent 25.0±24.0 25.0±21.0 25.0±18.0 25.0±15.0 25.0±12.0 25.0±9.0 Optionally, filler 25.0±24.0 25.0±21.0 25.0±18.0 25.0±15.0 25.0±12.0 25.0±9.0

[0131] In a particularly preferred embodiment, the adhesive material according to the invention comprises the following components in the following contents (embodiments B1 to B6):

[0132]

[0133]

[0134] In a preferred embodiment of the assembly according to the invention, the barrier element blocks the channel at the location for at least 5 minutes, preferably at least 10 minutes, preferably at least 15 minutes, more preferably at least 20 minutes, further more preferably at least 25 minutes, yet further more preferably at least 30 minutes, in each case after exposure to a temperature of 300° C., after expansion and curing of the adhesive material.

[0135] Preferably, the bonding material has a thermal degradation onset temperature of at least 250° C., preferably at least 300° C., preferably at least 310° C., more preferably at least 320° C., further more preferably at least 330° C., still further more preferably at least 340° C., most preferably at least 350° C. Preferably, the thermal degradation onset temperature is determined by thermogravimetric (TGA) analysis, preferably according to ASTM E2550.

[0136] In a preferred embodiment of the assembly according to the invention, the barrier element comprises a carrier.

[0137] Preferably, the carrier comprises a polymer selected from the group consisting of:

[0138] (i) polyamide (PA);

[0139] (ii) polybenzimidazole (PBI);

[0140] (iii) polydicyclopentadiene (pDCPD);

[0141] (iv) fluorinated polyolefins, preferably polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF);

[0142] (v) polyacrylic acid (PAA);

[0143] (vi) polyimide (PI), preferably polyetherimide (PEI), polyamideimide (PAI);

[0144] (vii) polysulfone (PSU), preferably polyethersulfone (PES), polyphenylsulfone (PPSU);

[0145] (viii) polyphenylene sulfide (PPS); and

[0146] (ix) Polyaryletherketone, preferably polyetherketone (PEK), polyetheretherketone (PEEK).

[0147] Preferably, the support comprises a metal.

[0148] When the blocking element includes a bonding material and a carrier, the bonding material can form a layer on the carrier on either or both sides of the carrier. Alternatively, the bonding material can be positioned along one or more edges of the carrier. Those skilled in the art recognize that various geometries of the carrier and the bonding material are possible in order to ensure that the blocking element blocks the passage at the position where it is attached to the inner wall of the hollow member when activated, i.e. expanded and cured. The carrier can be planar (i.e., having a flat form) or have a three-dimensional shape. At the position where the blocking element is attached to the inner wall of the hollow member, the periphery of the carrier can be similar to the periphery of the passage.

[0149] In a preferred embodiment of the assembly according to the present invention, the hollow component comprises or is essentially composed of: a structural member; preferably a frame of a vehicle or a part thereof; more preferably selected from the group consisting of pillars, fenders, floors, roofs, inner skirts, rear side panels and combinations thereof.

[0150] In a preferred embodiment of the assembly according to the invention, the channel is a branched pipe system comprising a first branch and a second branch.

[0151] Preferably, after expansion and curing of the adhesive material, the blocking element blocks the first branch of the channel at this position and provides a barrier to the gas, so that in the event of thermal runaway, the gas cannot pass through the first branch of the channel at this position and is guided to the second branch of the channel, which is preferably unblocked (i.e., unobstructed), so that in the event of thermal runaway, the gas can escape through the second branch.

[0152] Preferably, the first branch of the channel is connected to the passenger compartment of the vehicle in a gas-permeable manner prior to expansion and curing of the adhesive material.

[0153] Preferably, the second branch of the channel is not connected to the passenger compartment of the vehicle in a gas-permeable manner. Preferably, the second branch is unobstructed (ie unblocked) so that in the event of thermal runaway, gas can escape through said second branch. Preferably, the second branch is not blocked by a blocking element.

[0154] In a particularly preferred embodiment, the channel is a branched pipe system comprising a first branch and a second branch; wherein before expansion and curing of the adhesive material (during manufacturing operations of the vehicle or in the event of thermal runaway), the first branch of the channel is connected to the passenger compartment of the vehicle in a gas-permeable manner; wherein the second branch of the channel is not connected to the passenger compartment of the vehicle in a gas-permeable manner; and wherein the assembly is configured such that after expansion and curing of the adhesive material (during manufacturing operations of the vehicle or in the event of thermal runaway), the blocking element blocks the first branch of the channel at that position and provides a barrier to the gas, such that in the event of thermal runaway, the gas cannot pass through the first branch of the channel at that position and is directed to the second branch of the channel that is not blocked by the blocking element.

[0155] In a preferred embodiment, the second branch is connected to the exterior of the vehicle in a gas-permeable manner, so that in the event of thermal runaway, gas can escape from the channel through the second branch.

[0156] In other preferred embodiments, the second branch is not connected in a gas-permeable manner to the exterior of the vehicle, so that the gas is trapped within the hollow structure, for example in the second branch of the channel.

[0157] The battery module is not particularly limited and generally includes a plurality of battery cells mounted in a housing. The exhaust port is preferably located at the housing.

[0158] In a preferred embodiment of the assembly according to the invention, the battery modules are equipped with vents which, in the event of thermal runaway, enhance the release of gases from the battery modules through the exhaust ports and the propagation into the channels.

[0159] In a preferred embodiment of the assembly according to the invention, the vehicle is selected from the group consisting of a motor vehicle, a transport vehicle and a rail vehicle.

[0160] In a preferred embodiment of the assembly according to the invention, the adhesive material has expanded and cured and wherein the barrier element blocks the channel at one location.

[0161] Another aspect of the invention relates to a method for preparing a component for a vehicle according to the invention as described above, the method comprising the following steps:

[0162] (A) providing a battery module having a vent port through which gas is released in the event of thermal runaway;

[0163] (B) providing a hollow member defining an optionally branched channel connected to the exhaust port in a gas-permeable manner so that in the event of thermal runaway, gas released from the battery module through the exhaust port propagates into the channel;

[0164] (C) providing a barrier element comprising or consisting essentially of an expandable curable adhesive material;

[0165] (D) attaching a barrier element to at least a portion of an inner surface of a wall of the hollow member at a location of the passageway; and

[0166] (E) Optionally, the bonding material is expanded and cured so that the barrier element blocks the passage at that location and provides a barrier to the gas.

[0167] In a preferred embodiment of the method according to the invention, step (E) comprises heating the adhesive material to a temperature above its expansion activation temperature and above its curing activation temperature. Preferably, step (E) is carried out in a body-in-white oven and / or during an electrophoretic coating operation.

[0168] However, it is also conceivable that the expandable curable adhesive material maintains its expandable curable state, i.e. has not yet been activated, for example in a body-in-white oven and / or during an electrophoretic coating operation. Since the gases released from the battery module in the event of thermal runaway themselves have a relatively high temperature (e.g., above 300° C.), the heating effect of the gases propagating through the channel is sufficient to activate, i.e., expand and cure the adhesive material, thereby blocking the channel at the desired location.

[0169] Another aspect of the invention relates to the use of a barrier element according to the invention as described above, i.e., for providing a barrier to gas in an optionally branched channel; preferably in a component for a vehicle according to the invention as described above; wherein in the event of thermal runaway, gas is released from the battery module through the exhaust port and propagates into the channel.

[0170] Another aspect of the invention relates to the use of a barrier element according to the invention as described above, i.e. for guiding gas in an optionally branched channel; preferably in a component for a vehicle according to the invention as described above; wherein the gas is released from the battery module through the exhaust port in the event of thermal runaway and propagates into the channel.

[0171] Another aspect of the invention relates to the use of a barrier element according to the invention as described above, i.e. for protecting a passenger compartment of a vehicle from the effects of gases; in an optionally branched channel; preferably in a component for a vehicle according to the invention as described above; wherein gases are released from the battery module through the exhaust port in the event of thermal runaway and propagate into the channel.

[0172] By Figures 1 to 3The preferred embodiments schematically shown in the accompanying drawings further illustrate the present invention, which however should not be construed as limiting the scope of the present invention.

[0173] Figure 1 Schematically illustrated is an assembly having an adhesive material in its expandable, curable state (green state), i.e., before activation. A battery module (1) having a vent port (2) through which gas (3) is released in the event of thermal runaway, the vent port being connected in a gas-permeable manner to a hollow member (4), the hollow member defining an optionally branched channel (5) so that in the event of thermal runaway, gas (3) released from the battery module (1) through the vent port (2) propagates into the channel (5). A barrier element (6) comprising or essentially consisting of an expandable, curable adhesive material is attached to at least a portion of the inner surface of a wall of the hollow member (4) at a position of the channel (5) comprising a first branch (8) and a second branch (9).

[0174] Figure 2 Involved with Figure 1 The same embodiment, but schematically showing the assembly with the adhesive material in its expanded, solidified state, ie after activation. The barrier element (6) blocks the channel (5) at position (7).

[0175] Figure 3 Involved with Figure 2 The same embodiment, but schematically showing the assembly in the case of thermal runaway. Gas (3) is released from the battery module (1) through the exhaust port (3) and propagates into the channel (5). Due to the expanded solidified state of the adhesive material, the barrier element (6) blocks the first branch (8) of the channel (5), thereby providing a barrier to the gas (3). The gas (3) propagates into the channel (5) and is directed to the unblocked second branch (9) of the channel (5).

[0176] Figure 4 An experimental setup for testing the performance of a barrier element under laboratory conditions is schematically shown. A barrier element of a carrier (10) and an expanded, cured adhesive material (11) on one of its two surfaces is placed in a chamber. A temperature sensor (12) is arranged in front of the expanded, cured adhesive material (11). Heat is generated by a flame (14) and deflected by a heat deflector (13). Heat can be radiated from the flame (14) around the heat deflector (13) and enter the chamber containing the barrier element and the temperature sensor (12). The expanded, cured adhesive material (11) can be subjected to a certain temperature under controlled experimental conditions, and its structural integrity can be evaluated over time.

[0177] Reference numerals:

[0178] (1) Battery module

[0179] (2) Exhaust port

[0180] (3) Gas

[0181] (4) Hollow components

[0182] (5) Channel

[0183] (6) Barrier element

[0184] (7) Location

[0185] (8) First Branch

[0186] (9) Second Branch

[0187] (10) Carrier

[0188] (11) Expanded and cured adhesive material

[0189] (12) Temperature sensor

[0190] (13) Heat Deflector

[0191] (14) Flame

[0192] The following examples further illustrate the present invention but should not be construed as limiting its scope.

[0193] The barrier element is prepared by providing a polyamide carrier and applying an expandable curable adhesive material on one of its surfaces. The curable adhesive material comprises the following ingredients in the following amounts:

[0194]

[0195]

[0196] The barrier properties were tested for two different barrier elements. They were subjected to elevated temperatures (30 minutes at 165°C) to induce expansion and curing, just like in a body-in-white oven. The expanded and cured adhesive material layer (foam) of sample 1 had an average thickness of 5 mm, and sample 2 had an average thickness of 15 mm.

[0197] according to Figure 4 The thermal resistance was studied under various conditions and the results are shown in the following table:

[0198]

Claims

1. A component for a vehicle, the component comprising: - a battery module (1) having a vent port (2) through which gases (3) are released in the event of thermal runaway; - a hollow member (4) defining a channel (5) connected to the exhaust port (2) in a gas-permeable manner so that in the event of thermal runaway, the gas (3) released from the battery module (1) through the exhaust port (2) propagates into the channel (5); as well as - a barrier element (6) attached to at least a portion of the inner surface of the wall of the hollow member (4) at a position (7) of the passage (5) and comprising or essentially consisting of an expandable, curable adhesive material, the expandable, curable adhesive material being configured such that, after expansion and curing of the adhesive material, the barrier element (6) blocks the passage (5) at the position (7) and provides a barrier to the gas (3).

2. An assembly according to claim 1, wherein the expandable curable adhesive material is configured to expand and cure during the manufacturing operation of the vehicle, so that the vehicle includes the adhesive material in its expanded and cured state after its manufacture, and the blocking element (6) permanently blocks the channel (5) at the position (7) and provides a barrier to the gas (3).

3. An assembly according to claim 1, wherein the expandable curable adhesive material is configured to expand and cure when in contact with the gas (3) during thermal runaway, so that the vehicle initially comprises the material in its expandable and curable state after its manufacture, which material is transformed into its expanded and cured state in the event of thermal runaway.

4. Assembly according to any one of the preceding claims, wherein the channel (5) is branched.

5. An assembly according to any one of the preceding claims, wherein the adhesive material prior to expansion and curing is dry at 23°C and non-tacky to the touch.

6. An assembly according to any one of the preceding claims, wherein the bonding material after expansion and curing has a volume of at least 50% by volume.

7. An assembly according to any one of the preceding claims, wherein the bonding material after expansion and curing has a volume of at least 100% by volume.

8. An assembly according to any one of the preceding claims, wherein the bonding material after expansion and curing has a volume that is at least 150% by volume greater than its volume before expansion and curing.

9. An assembly according to any one of the preceding claims, wherein the bonding material has an expansion activation temperature in the range of 100°C to 200°C.

10. An assembly according to any one of the preceding claims, wherein the bonding material has a cure activation temperature in the range of 100°C to 200°C.

11. An assembly according to any one of the preceding claims, wherein the adhesive material comprises: (a) one or more monomers, prepolymers or polymers comprising reactive functional groups capable of undergoing a curing reaction; (b) a curing agent for use in (a); as well as (d) Foaming agent.

12. An assembly according to any one of the preceding claims, wherein the adhesive material comprises (a) one or more polymers comprising reactive epoxy functional groups; (b) a curing agent for use in (a); and (d) Foaming agent.

13. The assembly of claim 12, wherein the one or more polymers comprising reactive epoxy functional groups comprise or consist essentially of: One or more solid epoxy resins, one or more liquid epoxy resins, one or more glycidyl (meth)acrylate copolymers, one or more glycidyl (meth)acrylate terpolymers, or a mixture thereof.

14. The assembly according to claim 13, wherein the one or more solid epoxy resins and / or the one or more liquid epoxy resins are independently of each other diglycidyl ethers of bisphenol (DGEB), preferably diglycidyl ether of bisphenol A (DGBEA) and / or diglycidyl ether of bisphenol F (DGBEF).

15. The assembly according to any one of claims 12 to 14, wherein the total content of the one or more polymers comprising reactive epoxy functional groups is in the range of 30±25 wt.-%, preferably 30±20 wt.-%, more preferably 30±15 wt.-%, further more preferably 30±10 wt.-%, yet further more preferably 30±5 wt.-%, in each case relative to the total weight of the bonding material.

16. The component according to any one of claims 11 to 15, wherein the curing agent is selected from the group consisting of aliphatic amines, alicyclic amines, aromatic amines, modified polyamines, unmodified polyamines, modified polyamides, unmodified polyamides, blocked amines, amidoamines, acid anhydrides, polycarboxylic acid polyesters, isocyanates, phenolic resins, phenol novolac resins, cresol novolac resins, copolymers of phenol terpenes, polyvinylphenol, bisphenol A formaldehyde copolymers, bishydroxyphenylalkane, hydrazide, sulfone, diaminodiphenyl sulfone, or mixtures thereof; preferably guanidine; more preferably selected from the group consisting of dicyandiamide (cyanoguanidine), methylguanidine, dimethylguanidine, trimethylguanidine, tetramethylguanidine, methylisobiguanide, dimethylisobiguanide, tetramethylisobiguanide, hexamethylisobiguanide, heptamethylisobiguanide, and mixtures thereof; further more preferably dicyandiamide.

17. An assembly according to any one of the preceding claims, wherein the adhesive material comprises (a) one or more monomers or prepolymers comprising ethylenically unsaturated functional groups, typically acrylic groups; (b) a curing agent for use in (a); and (d) Foaming agent.

18. The assembly according to claim 17, wherein the monomer or prepolymer comprising an ethylenically unsaturated functional group is selected from (meth)acrylic acid, (meth)acrylic acid C 1-6 -alkyl ester, (meth) acrylate hydroxy C 1-6 -alkyl esters, cycloalkyl (meth)acrylates, and mixtures thereof.

19. The assembly according to claim 17 or 18, wherein the curing agent is selected from N,N-dimethyl-p-toluidine (DMPT), N-(2-hydroxyethyl)-N-methyl-p-toluidine (MHPT), N-methyl-N-(2-hydroxypropyl)-p-toluidine (2HPMT) and N-ethyl-N-(2-hydroxyethyl)-p-toluidine (EHPT); more preferably N-methyl-p-toluidine derivatives, N-(2-hydroxyethyl)-N-methyl-p-toluidine, N-ethyl-N-(2-hydroxyethyl)-p-toluidine, or any combination thereof.

20. An assembly according to any one of the preceding claims, wherein the adhesive material comprises (a) one or more monomers, prepolymers or polymers comprising isocyanate and / or hydroxyl functional groups; (b) a curing agent for use in (a); and (d) Foaming agent.

21. The assembly according to any one of claims 11 to 20, wherein the blowing agent is a chemical blowing agent; preferably selected from the group consisting of azodicarbonamide, dinitrosopentamethylenetetramine, 4,4'-oxy-bis-(benzenesulfonylhydrazide), trihydrazino-s-triazine, and N,N'-dimethyl-N,N'-dinitrosoterephthalamide; more preferably azodicarbonamide.

22. The assembly of any one of claims 11 to 21, wherein the adhesive material further comprises (c) a curing agent activator.

23. The assembly of claim 22, wherein the curing agent activator is selected from the group consisting of: modified or unmodified ureas, imidazoles and mixtures thereof; preferably methylene diphenyl bisurea.

24. The assembly of any one of claims 11 to 23, wherein the adhesive material further comprises (e) a blowing agent activator.

25. The assembly of any one of claims 11 to 24, wherein the bonding material further comprises (f) one or more additional polymers; preferably, one or more polymers that do not include reactive epoxy functional groups.

26. The assembly of claim 25, wherein the one or more polymers not comprising reactive epoxy functional groups comprise or consist essentially of: One or more ethylene (meth)acrylate copolymers, one or more ethylene vinyl acetate copolymers, and mixtures thereof.

27. Assembly according to claim 25 or 26, wherein the total content of the one or more polymers not comprising reactive epoxy functional groups is in the range of 5.0±4.5 wt. % relative to the total weight of the bonding material.

28. The assembly of any one of claims 11 to 27, wherein the bonding material further comprises (g) one or more toughening agents.

29. The assembly of claim 28, wherein the one or more toughening agents comprises or consists essentially of: (i) ethylene methacrylate copolymers and / or (ii) epoxy / elastomer adducts; preferably, wherein the epoxy is diglycidyl ether of bisphenol (DGEB), and wherein the elastomer is selected from the group consisting of carboxy-terminated butadiene acrylonitrile rubber (CTBN), carboxy-terminated polybutadiene (CTPB), hydroxy-terminated butadiene acrylonitrile rubber (HTBN), hydroxy-terminated polybutadiene (HTPB), amine-terminated butadiene acrylonitrile rubber (ATBN), epoxidized hydroxy-terminated polybutadiene (EHTPB), and mixtures thereof; more preferably, wherein the epoxy is diglycidyl ether of bisphenol A (DGBEA) or diglycidyl ether of bisphenol F (DGBEF), and wherein the elastomer is carboxy-terminated butadiene acrylonitrile rubber (CTBN).

30. The component according to claim 28 or 29, wherein the total content of the one or more toughening agents is in the range of 25±20 wt.-%, preferably 25±15 wt.-%, more preferably 25±10 wt.-%, even more preferably 25±5 wt.-%, in each case relative to the total weight of the bonding material.

31. The assembly of any one of claims 11 to 30, wherein the bonding material further comprises (h) one or more fillers.

32. The assembly of claim 31, wherein the one or more fillers comprise or consist essentially of: Calcium oxide, magnesium oxide, calcium carbonate, magnesium carbonate, talc, wollastonite, bentonite, kaolin, mica, powdered quartz, fumed silica, silica aerogel, coal tar, carbon black, glass particles, textile fibers, glass fibers, aramid fibers, aramid pulp, boron fibers, carbon fibers, and mixtures thereof.

33. A component according to claim 31 or 32, wherein the total content of the one or more fillers is in the range of 30±25 wt.-%, preferably 30±20 wt.-%, more preferably 30±15 wt.-%, further more preferably 30±10 wt.-%, yet further more preferably 30±5 wt.-%, in each case relative to the total weight of the adhesive material.

34. An assembly according to any one of claims 11 to 33, wherein the adhesive material further comprises (i) one or more flame retardants and / or smoke suppressants.

35. Assembly according to any one of the preceding claims, wherein the barrier element (6) comprises a carrier.

36. A component according to claim 35, wherein the carrier comprises a polymer selected from the group consisting of: (i) polyamide (PA); (ii) polybenzimidazole (PBI); (iii) polydicyclopentadiene (pDCPD); (iv) fluorinated polyolefins, preferably polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF); (v) polyacrylic acid (PAA); (vi) polyimide (PI), preferably polyetherimide (PEI), polyamideimide (PAI); (vii) polysulfone (PSU), preferably polyethersulfone (PES), polyphenylenesulfone (PPSU); (viii) polyphenylene sulfide (PPS); and (ix) polyaryletherketone, preferably polyetherketone (PEK), polyetheretherketone (PEEK); preferably polyamide (PA).

37. An assembly according to claim 35 or 36, wherein the carrier comprises a metal.

38. Assembly according to any of the preceding claims, wherein the hollow member (4) comprises or consists essentially of a structural member.

39. An assembly according to claim 38, wherein the structural member: is a frame of the vehicle or a part thereof; preferably selected from the group consisting of pillars, fenders, floors, roofs, inner skirts, rear quarter panels and combinations thereof.

40. Assembly according to any one of the preceding claims, wherein the channel (5) is a branched duct system comprising a first branch (8) and a second branch (9).

41. The component according to claim 40 is configured such that, after the adhesive material expands and cures, the blocking element (6) blocks the first branch (8) of the channel (5) at the position (7) and provides a barrier to the gas (3), so that in the event of thermal runaway, the gas (3) cannot pass through the first branch (8) of the channel (5) at the position (7) and is guided to the second branch (9) of the channel (5).

42. An assembly according to claim 40 or 41, configured so that, before the adhesive material expands and cures, the first branch (8) of the channel (5) is connected to the passenger compartment of the vehicle in a gas-permeable manner.

43. Assembly according to any one of claims 40 to 42, wherein the second branch (9) of the channel (5) is not connected in a gas-permeable manner to the passenger compartment of the vehicle.

44. Assembly according to any one of claims 40 to 43, wherein the second branch (9) of the channel (5) is unobstructed.

45. Assembly according to any one of claims 40 to 44, wherein the second branch (9) of the channel (5) is not blocked by a blocking element (6).

46. ​​A component according to any one of the preceding claims, wherein the channel (5) is a branched pipe system including a first branch (8) and a second branch (9); wherein before the adhesive material expands and cures, the first branch (8) of the channel (5) is connected to the passenger compartment of the vehicle in a gas-permeable manner; wherein the second branch (9) of the channel (5) is not connected to the passenger compartment of the vehicle in a gas-permeable manner; and wherein the component is configured so that after the adhesive material expands and cures, the blocking element (6) blocks the first branch (8) of the channel (5) at the position (7) and provides a barrier to the gas (3), so that in the event of thermal runaway, the gas (3) cannot pass through the first branch (8) of the channel (5) at the position (7) and is guided to the second branch (9) of the channel (5) that is not blocked by the blocking element.

47. Assembly according to any one of claims 40 to 46, wherein the second branch (9) is connected to the exterior of the vehicle in a gas-permeable manner, such that the gas (3) can escape from the channel (5) through the second branch (9).

48. Assembly according to any one of claims 40 to 46, wherein the second branch (9) is not connected to the exterior of the vehicle in a gas-permeable manner, so that the gas (3) is trapped in the second branch (9) of the channel (5).

49. A component according to any of the preceding claims, wherein the battery module (1) is equipped with a vent, which is configured to enhance the release of the gas (3) from the battery module (1) through the exhaust port (2) and the propagation into the channel (5) in the event of thermal runaway.

50. The assembly of any preceding claim, wherein the vehicle is selected from a motor vehicle, a transportation vehicle, and a rail vehicle.

51. A method for preparing a component for a vehicle according to any one of the preceding claims, the method comprising the steps of: (A) providing a battery module (1) having a vent port (2), through which gas (3) is released in the event of thermal runaway; (B) providing a hollow member (4) defining an optionally branched channel (5), the channel (5) being connected to the exhaust port (2) in a gas-permeable manner so that in the event of thermal runaway, the gas (3) released from the battery module (1) through the exhaust port (2) propagates into the channel (5); (C) providing a barrier element (6) comprising or consisting essentially of an expandable curable adhesive material; (D) attaching the barrier element (6) to at least a portion of the inner surface of the wall of the hollow member (4) at the location (7) of the passage (5); and (E) Optionally, the adhesive material is expanded and cured so that the barrier element (6) blocks the passage (5) at the location (7) and provides a barrier to the gas (3).

52. The method of claim 51, wherein step (E) comprises heating the bonding material to a temperature above its expansion activation temperature and above its cure activation temperature.

53. The method of claim 51 or 52, wherein step (E) is performed in a body-in-white oven and / or during an electrophoretic coating operation.

54. The use of a barrier element (6) as defined in any one of claims 1 to 50 for providing a barrier to gas (3) in an optionally branched channel (5); preferably in a component for a vehicle according to any one of claims 1 to 50; wherein the gas (3) is released from the battery module (1) through the exhaust port (2) in the event of thermal runaway and propagates into the channel (5).

55. Use of a barrier element (6) as defined in any one of claims 1 to 50 for guiding gas (3) in an optionally branched channel (5); preferably in a component for a vehicle according to any one of claims 1 to 50; wherein the gas (3) is released from the battery module (1) through the exhaust port (2) in the event of thermal runaway and propagates into the channel (5).

56. Use of a barrier element (6) as defined in any one of claims 1 to 50 for protecting a passenger compartment of a vehicle from gas (3) in an optionally branched channel (5); preferably in a component for a vehicle according to any one of claims 1 to 50; wherein the gas (3) is released from the battery module (1) through the exhaust port (2) in the event of thermal runaway and propagates into the channel (5).

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