Thermal insulation device

Abstract

The invention relates to a heat insulation device which comprises functional filler packaged in a bag body. The bag body is made of a membrane material; the membrane material at least comprises an inorganic fiber layer; and a polymer layer, wherein the inorganic fiber layer is laminated on the polymer layer. The bag body includes a sealing side formed by sealing the film material. And the functional filler is packaged in the bag body, so that the functional filler cannot escape from the sealing side edge of the bag body. The functional filler comprises insulating particles in powder form.

Description

Technical Field

[0001] The present invention relates to a framed or frameless thermal insulation device / product. One or more flame retardant sheets and / or coatings can be added to the thermal insulation device to further enhance its performance. The thermal insulation device / product can be used in batteries, such as the batteries of electric vehicles. Background Art

[0002] Existing thermal insulation devices containing aerogel as the core material and used in batteries are usually made of aerogel felt. Aerogel felt is composed of a non-woven matrix, which serves as a reinforcing material for aerogel and has a wide application in the energy infrastructure market. The characteristics of aerogel felt make it very suitable as a thermal insulation device for process pipelines because of its unique ability to resist corrosion under insulation (CUI), but it has poor effects in batteries, especially in battery electric vehicles. The non-woven matrix of aerogel felt can affect the thermal insulation performance and mechanical properties, especially under extremely high compression conditions, which may damage the inorganic fibers and change the compression characteristics of aerogel felt. Summary of the Invention

[0003] According to an embodiment of the present disclosure, there is provided a thermal insulation device as described in the independent claims and a battery including the thermal insulation device. Some optional features are defined in the dependent claims. Brief Description of the Drawings

[0004] Embodiments of the present disclosure will be better understood by those skilled in the art through the following written description, by way of example and in conjunction with the drawings. In the drawings:

[0005] Figure 1 A thermal insulation device according to an embodiment of the present disclosure is shown.

[0006] Figure 2 A thermal insulation device according to another embodiment of the present disclosure is shown.

[0007] Figure 3a -b shows the membrane structure of the thermal insulation device according to an embodiment of the present disclosure.

[0008] Figure 4 A membrane material layer according to an embodiment of the present disclosure is shown.

[0009] Figure 5a -b shows a bag body of the thermal insulation device with four sealed sides according to an embodiment of the present disclosure.

[0010] Figure 6 The bottom view and top view of a bag body of the thermal insulation device with three sealed sides according to an embodiment of the present disclosure are shown.

[0011] Figure 7aShows an example of the pre - folding (corner folding) of the bag body of the heat insulation device according to an embodiment of the present disclosure.

[0012] Figure 7b Shows a front view of the pre - folded (corner - folded) bag according to an embodiment of the present disclosure.

[0013] Figure 8a -b shows the sealing edge of the bag body of the heat insulation device according to an embodiment of the present disclosure.

[0014] Figure 9a -d shows an example of the tape or adhesive applied to the heat insulation device.

[0015] Figure 10a -c shows an example of a composition comprising a heat insulation device, a flame retardant device, and / or an expansion sheet / coating according to an embodiment of the present disclosure.

[0016] Figure 11a -b shows the steps of forming and sealing the bag body frame of the heat insulation device according to an embodiment of the present disclosure.

[0017] Figure 12a -b shows a frame - type heat insulation device according to an embodiment of the present disclosure.

[0018] Figure 13a -b shows another frame - type heat insulation device according to an embodiment of the present disclosure.

[0019] Figure 14 Shows Figure 12a -b and Figure 13a Possible dimensions of the frame - type heat insulation device examples of -b.

[0020] Figure 15 Shows the front view, rear view, and side view of the first example of the heat insulation device with a flipped or folded seal according to an embodiment of the present disclosure.

[0021] Figure 15a Shows the front view, rear view, and side view of the second example of the heat insulation device with a flipped or folded seal according to an embodiment of the present disclosure.

[0022] Figure 15b Shows the front view, rear view, and side view of the third example of the heat insulation device with a flipped or folded seal according to an embodiment of the present disclosure.

[0023] Figure 15c Shows the front view, rear view, and side view of the fourth example of the heat insulation device with a flipped - type sealing structure according to an embodiment of the present disclosure.

[0024] Figure 16Shows a graph of the weight of an E - glass fiber sample varying with temperature.

[0025] Figure 17 Shows a graph of the mass percentage of a heat - insulating device with a PET / EG / PE film structure varying with temperature.

[0026] Figure 18 Shows a table comparing the performance data of heat - insulating devices with PET / EG / PE and PET / AL / PE film structures respectively. Detailed implementation mode

[0027] In the present disclosure, an electric vehicle (EV) refers to a vehicle driven by one or more electric motors and usually powered by a battery. Such EVs are also referred to as battery - electric vehicles (BEVs). Electric vehicles include, but are not limited to, road and rail vehicles (such as electric scooters, electric bicycles, electric cars, space exploration vehicles, etc.), water and underwater vessels, electric aircraft (such as manned / unmanned airplanes and aerial drones, etc.), and electric spacecraft.

[0028] In the present disclosure, a heat - insulating device with a compressible heat - insulating layer is provided. The heat - insulating layer contains, for example, aerogel and is applicable to, but not limited to, EV batteries. The heat - insulating device is relatively lightweight in the application of electric vehicle batteries. The term "heat - insulating device" throughout the present disclosure refers to the described heat - insulating device.

[0029] An example of the heat - insulating device 100 is Figure 1As shown. The heat insulation device is a bag (or bladder, packet, package, pouch, container) filled with aerogel and sealed into a "blade" structure. The bag 100 includes three membrane material layers FML1 101, FML2 102, and FML3 103. Among them, the membrane material layer FML1 101 is the covering layer, the membrane material layer FML3 103 is the inner layer, and the membrane material layer FML2 102 is disposed between the membrane material layer FML1 101 and FML3 103. The membrane material layer FML1 101 is an optional structure and can be used to protect the heat insulation device from the external environment. The membrane material layer FML2 102 can insulate heat and fire, and provide mechanical strength as the reinforcement layer of the heat insulation device 100. The membrane material layer FML3 103 is used to maintain the shape of the heat insulation device 100. In one embodiment, the membrane material layer FML3 can also improve the heat insulation performance of the heat insulation device 100 and form an internal structure capable of maintaining the uniform distribution state of the functional filler. There may be perforations (or holes, micropores, pores, openings, or orifices, not shown) in the membrane material layer. The average diameter of the perforations (or holes, micropores, pores, openings, or orifices) can be 15 μm or less. In another embodiment, the membrane material layer FML3 and / or one or more other layers can have the following characteristics: when heated and cooled and formed in the subsequent heating and cooling steps described (see step (17) in the example of the heat insulation device manufacturing process), the perforations are sealed. The edges of the membrane material layer are sealed to form the bag 100, which can accommodate the functional filler. The functional filler can mainly include heat insulation particles. In the present disclosure, "membrane material" and "membrane structure" can be used interchangeably.

[0030] For example, the first functional filler FF1 can include at least one of aerogel powder, fumed silica, and glass microspheres. The aerogel powder contains fine silica (SiO2) particles with a diameter of 100 μm or less. FF1 is heat insulation particles in powder form.

[0031] The second functional filler FF2 can include at least one of titanium dioxide (TiO2), iron oxide (Fe2O3), and aluminum oxide (Al2O3). Its function is to inhibit the increase in the thermal conductivity coefficient of the heat insulation device in a high-temperature environment, thereby improving the heat insulation performance.

[0032] The third functional filler FF3 can include at least one of magnesium hydroxide (MDH), aluminum hydroxide (ATH), and zinc borate. When placed in an EV battery and a fire occurs in the battery pack, the functional filler 3 can decompose and release non-combustible gases such as water, nitrogen, ammonia, or carbon dioxide during the combustion process, thereby cooling and diluting oxygen, and at the same time generating moisture, which can delay the fire.

[0033] In one embodiment, FF1 is the key component, while FF2 and FF3 are optional components. They need to be uniformly or homogeneously mixed before being filled into the bag of the heat insulation device 100.

[0034] The fourth functional filler FF4 114 may be a reinforcing fiber that coats the functional fillers FF1, FF2, and FF3 123 and is adjacent to the film material layer FML3 103. The functional filler FF4 114 includes at least one of glass fiber, quartz wool, mineral wool, ceramic wool, woven fiber, and non-woven fiber. FF4 may also be an acrylic resin-bonded glass fiber veil, which may be a continuous filament glass fiber product. FF4 114 is an optional layer. FF4 114 may be referred to as the innermost layer in the present disclosure because it contacts FF1, FF2, and / or FF3. If FF4 114 does not exist, then FML3 103 will become the innermost layer.

[0035] Table 1 below shows an example of the composition of the heat insulation device.

[0036] Table 1:

[0037]

[0038] In the present disclosure, inorganic fiber refers to a fiber made of an inorganic material, which includes glass, carbon (referring to the inorganic type), ceramic, basalt, asbestos, alumina, wollastonite, potassium titanate, silicon carbide, etc. alone or in combination.

[0039] An adhesive may be used between the film material layers, and the film material layers are laminated into a single sheet. In some embodiments, due to the too high lamination temperature, the polymer in a certain film material layer may penetrate into another film material layer (especially when using woven inorganic fiber), resulting in the blurred boundary between layers. Therefore, in the actual physical product, each layer may not be as Figure 1 distinct and neatly stacked as shown, and there may be partial overlap or mixing of the materials of each layer.

[0040] By using woven inorganic fiber (such as E-glass fiber) with a very low organic binder content (about 0.05 wt% to 1 wt%) as a component of the thin film material or filler, the overall organic content of the finally obtained heat insulation device is reduced, thereby obtaining more excellent heat resistance and fire resistance, while maintaining good dielectric properties and mechanical strength. To obtain higher tensile strength, S-glass fiber can be used. If higher thermal resistance is required, T-glass fiber can be used.

[0041] According to the composition and structure of the embodiments shown in Table 1, the typical installation density of the heat insulation device in the compressed battery module assembly is about 0.2 to 0.5 g / cm 3 . In the relaxed state without pressure, the apparent density of the heat insulation device is about 0.05 to 0.4 g / cm 3 .

[0042] For example, the thermal insulation device 100 can be made through the following simplified manufacturing process overview.

[0043] 1. Homogeneously mix the functional fillers FF1, FF2, and FF3.

[0044] 2. Laminate the film material layers FML1, FML2, and FML3 to form a single sheet, with the film material layers FML1 and FML3 on both sides of the film material layer FML2 respectively. A thermosensitive / pressure-sensitive adhesive may or may not be used between the layers. A roll-to-roll thermal lamination process can be adopted.

[0045] 3. Form holes (perforations) in the single sheet, for example, using a needle roller (or punch).

[0046] 4. Use methods such as heat fusion to form a bag-like structure with a single opening through the film material layer FML3, with the outermost layer being the film material layer FML1.

[0047] 5. Arrange the functional filler FF4 near the inner surface of the bag to form a void.

[0048] 6. Place the mixture of the functional fillers FF1, FF2, and FF3 into the cavity, and wrap the mixture with the functional filler FF4.

[0049] 7. Close and seal the opening of the bag using methods such as heat fusion to form a thermal insulation device in the "blade" structure.

[0050] The following are some examples of the thermal insulation device 100.

[0051] See Figure 2 , which shows an example of the thermal insulation device 200. The thermal insulation device 200 can have a membrane structure (or membrane material), including an outer layer 201 (for example, for resisting external environmental conditions; corresponding to FML1), an intermediate layer 202 (for example, for providing mechanical strength and heat and fire insulation protection; corresponding to FML2), and an inner layer 203 (for example, for locking the distribution of the fillers in the cavity and maintaining the shape of the bag; corresponding to FML3). Perforations 210 (or called holes, micropores, pores, openings, or orifices) are provided on the film material layers FML1, FML2, and FML3 201, 202, and 203. The average diameter of the perforations (or holes, pores, openings, or orifices) can be about 15 μm or less. The perforations (or holes, pores, openings, or orifices) can allow air to escape from the thermal insulation device 200. The edges of the film material layers are sealed to form a bag containing functional fillers. The functional filler FF4 214 can be used as a reinforcing fiber for coating the functional fillers FF1, FF2, and FF3 223 and is adjacent to the thin film material layer FML3 203.

[0052] Figure 3a Shows Figure 1The insulation device 100 shown or Figure 2 An example of the membrane structure (or membrane material) 300a of the insulation device 200 shown includes a first polymer layer 301 (corresponding to FML1) as the outer layer, an inorganic membrane layer 302 (corresponding to FML2) as the intermediate layer, and a second polymer layer 303 (corresponding to FML3) as the inner layer. Layers 301, 302, and 303 are joined by an adhesive 350.

[0053] Figure 3a An example of the membrane structure (or membrane material) 300a of the insulation device shown includes a polymer layer (corresponding to FML1) as the outer layer, a woven inorganic fiber (glass fiber) layer (corresponding to FML2) as the intermediate layer, and another polymer layer (corresponding to FML3) as the inner layer. Such insulation devices exhibit excellent properties such as good heat resistance and fire resistance, while maintaining excellent dielectric properties and mechanical strength.

[0054] Figure 3b Shows Figure 1 Another example of the membrane structure 300b of the insulation device 100 shown includes an inorganic membrane layer 312 (corresponding to FML2) as the outer layer and a second polymer layer 313 (corresponding to FML3) as the inner layer. The polymer layer 313 is partially melted and mixed or penetrated into the inorganic membrane layer 312. Such melting, mixing, and penetration can be achieved by, for example, thermal lamination. In particular, there is no distinct boundary between the inorganic membrane layer 312 and the second polymer layer 313.

[0055] In other embodiments, Figure 2 the membrane material layer FML2, the intermediate layer 202, Figure 3a the inorganic membrane layer 302 in Figure 3b and the inorganic membrane layer 312 in

[0056] Table 1a below shows various tests conducted to compare the performance of insulation devices with PET / AL / PE and PET / EG / PE membrane structures. PET / AL / PE refers to a membrane structure having a polyethylene terephthalate (PET) layer, an aluminum (AL) layer, and a polyethylene (PE) layer. PET / EG / PE refers to a membrane structure having a polyethylene terephthalate (PET) layer, a glass fiber (EG) layer (such as an E-glass woven or non-woven fabric, cloth, or felt) layer, and a polyethylene (PE) layer.

[0057] Table 1a: Comparison of EG and AL

[0058]

[0059] The tensile strength and thermal conductivity of PET / AL / PE and PET / EG / PE are shown in Table 1b below.

[0060] Table 1b: Comparison between membrane materials PET / AL / PE and PET / EG / PE

[0061]

[0062] The following Table 1c lists the thermal conductivity of the heat insulation devices made of PET / AL / PE and PET / EG / PE membrane materials, which are filled (filled with heat insulation particles such as aerogel powder) and heat-treated.

[0063] Table 1c: Comparison of heat insulation devices made of PET / AL / PE membrane material and PET / EG / PE membrane material

[0064]

[0065] The above Tables 1a to 1c show that the PET / EG / PE material is superior to the PET / AL / PE material in terms of electrical insulation, tensile strength, and thermal conductivity. The main contributing factor lies in the use of the inorganic fiber layer, i.e., EG.

[0066] As shown in Table 1a, the thermal stability, thermal conductivity, and electrical conductivity parameters of the raw materials (i.e., aluminum foil and EG woven felt) are listed. Aluminum melts at about 660 °C, while the EG woven felt shows no sign of degradation up to 1000 °C in the thermogravimetric analysis (TGA-air) test in air. This indicates that EG has better thermal stability at high temperatures compared to aluminum. The thermal conductivity of the EG woven felt is much lower than that of the aluminum foil. The EG woven felt is a good electrical insulator, while aluminum is an excellent electrical conductor.

[0067] The tensile strength of the perforated membrane and the thermal conductivity of the PET / AL / PE and PET / EG / PE membrane materials were studied. As shown in Table 1b, the tensile strength of PET / EG / PE is much higher than that of PET / AL / PE, both in the single-layer lamination direction and the single-layer transverse direction. The thermal conductivity of PET / EG / PE is much lower than that of PET / AL / PE.

[0068] In addition, the thermal conductivity of the bags made of PET / AL / PE and PET / EG / PE composite membranes after being filled and heat-treated was also studied. As shown in Table 1c, the thermal conductivity of PET / EG / PE at 24 °C and 50 °C is lower than that of PET / AL / PE.

[0069] Refer to Figure 16 , the weight of the EG woven felt sample was measured as the temperature increased from 25 °C to 1000 °C. It can be seen that even when the temperature is at the lowest weight value at 815 °C, the weight change is only 0.78% of the initial weight. This indicates that the weight change of EG is not significant in the temperature range of 25 °C to 1000 °C.

[0070] Reference Figure 17 , the mass of the heat insulation device with a PET / EG / PE film structure was measured when the temperature was raised from 25 °C to 1000 °C. It can be seen that the mass of the heat insulation device remained almost constant in the temperature range of 25 °C to 260 °C. This indicates that the heat insulation device remained stable in the temperature range far above the battery operating temperature and the thermal runaway temperature. Reference Figure 17 , the residue weight remained at 23% from 600 °C to 1000 °C, and this weight was mainly contributed by EG. This indicates that the EG woven felt can still provide sufficient heat resistance as the outer shell material of the heat insulation device after experiencing thermal runaway with a maximum temperature usually of 900 °C.

[0071] As Figure 18 shown in the table, the thermal conductivity of two groups of heat insulation device samples (TB301-2mm) with a PET / EG / PE film structure and two groups of another heat insulation device samples (Al-2mm) with a PET / AL / PE film structure was measured using a heat flow meter (HFM). In the table, the measured thickness = the thickness of each sample measured under the load pressure and average temperature; the thermal conductivity = the heat flux per unit area / the temperature gradient; the thermal resistance = the thickness / the thermal conductivity.

[0072] At two load pressures of about 2 kPa (i.e., 1.9 kPa and 2.3 kPa) and two temperatures of 24 °C and 50 °C, the thermal conductivities of sample 1 of TB301-2mm with a thickness of 2.359 mm were 0.01405 W / m·K and 0.01503 W / m·K respectively, and the thermal resistances were 0.1679 m 2 K / W and 0.157 m 2 K / W. At two load pressures of about 23 kPa (i.e., 23 kPa and 23.8 kPa) and two temperatures of 24 °C and 50 °C, the thermal conductivities of sample 2 of TB301-2mm with a thickness of 2.313 mm were 0.01517 W / m·K and 0.01586 W / m·K respectively, and the thermal resistances were 0.1525 m 2 K / W and 0.1459 m 2 K / W.

[0073] At two load pressures of about 2 kPa (i.e., 2.2 kPa and 2.4 kPa) and two temperatures of 24 °C and 50 °C, the thermal conductivities of sample 3 of Al-2mm with a thickness of 2.349 mm were 0.01569 W / m·K and 0.01613 W / m·K respectively, and the thermal resistances were 0.1497 m 2 K / W and 0.1457 m 2K / W. Under two load pressures of about 23 kPa (i.e., 22.9 kPa and 23.6 kPa) and two temperatures of 24°C and 50°C, the thermal conductivity of Al-2 mm sample 4 with a thickness of 2.301 mm is 0.01593 W / m·K and 0.01663 W / m·K, respectively, and the thermal resistance is 0.1445 m 2 K / W and 0.1384m 2 K / W.

[0074] Therefore, at similar thickness, the thermal conductivity values of the PET / EG / PE device are lower than those of the PET / AL / PE device at both load pressures of about 2 kPa and at both temperatures of 24 °C and 50 °C. In addition, the thermal resistance of the PET / EG / PE device is higher than that of the PET / AL / PE device. This indicates that PET / EG / PE provides higher resistance to thermal conduction.

[0075] The above studies show that a thermal insulation device (not limited to EG) with an inorganic fiber film (or layer) covered on an aluminum film or aluminum layer exhibits excellent performance, such as good heat resistance and fire resistance, while maintaining excellent dielectric properties and mechanical strength. Therefore, the device is a good choice for battery insulation and thermal runaway management of electric vehicles.

[0076] about Figure 2 , 3a In the embodiment shown in 3b, two membrane structures can be arranged opposite to each other and sealed at the sides, and then filled with functional fillers to form a bag. The filler can be a free-flowing filler, such as an aerogel-based material, i.e., FF1, and can contain additives such as FF2 and / or FF3. For example, the filler flows freely in the form of a powder. The filler may also include reinforcing fibers coating the free-flowing fillers FF1, FF2 and / or FF3, and the reinforcing fibers are adjacent to the membrane material layer FML3. In all examples of the membrane structure described in the present disclosure, a plurality of holes or perforations can be provided to achieve ventilation and / or degassing purposes. In order to provide sufficient ventilation / pressure relief channels, the center spacing of the perforations may be about 3×3 mm. Figure 4 An example of a surface of a layer of film material 400 with perforations 410 is shown. Figure 5a An example of a bag 500 made from this film structure is shown, having a four-side seal 570 . Figure 5b 5. The seal area of each seal 570 of the bag 500 can have a seal width of about 6 mm along the outer edge of the bag body 550. Other types of seals may also be applicable. For example, the bag can be a three-side sealed bag, which will be described below.

[0077] Figure 6 A bottom view of an example of a bag body 600 is shown. Figure 6 A and top view Figure 6B. The bag body is rectangular and has a three-side sealing structure. Bag bodies of other shapes are also applicable. The three-side sealing structure includes a longitudinal or central (linear) seal 660, and two side (linear) seals, namely a top seal 663 and a bottom seal 665. The longitudinal seal 660 is disposed between the two side seals 663 and 665, and is connected to the two side seals 663 and 665 at the ends of the longitudinal seal 660. The longitudinal seal 660 can be regarded as orthogonal to the two side seals 663 and 665, and the side seals are horizontally disposed relative to the sides of the bag body 600. For example, the seals 660, 663, and 665 of the bag body may have a sealing width of about 10 - 20 mm.

[0078] An example of the formation process of the bag body 600 is outlined as follows. A film material is prepared in advance, which may have, for example, the film structures of the embodiments described in Table 1 above and Figure 1 , 2 , as shown in 3a and 3b. The film material from a roll of film is curled to form a tubular structure, and the two opposite sides of the film material are joined by the longitudinal seal 660. After the longitudinal seal 660 is sealed, the bottom seal 665 is then sealed, thereby forming a preformed bag body with an open top side or top end. The functional filler FF4 can be disposed near the inner surface of the preformed bag body through the open top side or top end of the preformed bag body to form a void. The powder or mixture of the functional fillers (such as FF1, FF2, and / or FF3) is metered or fed into the preformed bag body through the open top side or top end, and the mixture is wrapped by the functional filler FF4. After the preformed bag body is filled, the top seal 663 is sealed to close the opening of the open top side or top end. Alternatively, the filling of the functional filler FF4 is skipped, and only FF1, FF2, and / or FF3 are filled into the preformed bag body.

[0079] Preferably, the horizontal seal, or the top seal 763 and the bottom seal 765, can be folded or turned over at the positions of the sealed corners of the preformed bag body 700, as Figure 7a shown. This folding or turning over of the sealed corners is called pre-folding. Other pre-folding configurations may also be applicable. For example, only the corners of one of the top and bottom seals are pre-folded. In another embodiment, only one corner of the top or bottom seal is pre-folded. For a square or rectangular bag body, each corner refers to each of the four sharp corners. Pre-folding can be performed to prevent leakage of the filler powder / mixture at the corners of each bag body. Pre-folding is an optional but recommended operation. Pre-folding can be combined with heat treatment to soften the film material while applying pressure to fold the corners. This can keep the folded corners fixed and prevent them from unfolding by themselves.

[0080] Figure 7b Shows Figure 7aFront view of the pre-folded (corner-folded) bag body 700. In one embodiment, a tape or adhesive 790 is applied to the sealing area at the hem (or sealed side) of the bag body, specifically the top seal (or sealing area) 763 or the bottom seal (or sealing area) 765 of the bag body, which are also referred to as the horizontal sealing areas of the bag body. For example, a double-sided tape (or tape without a substrate) can be used at the hem of the bag body. In another embodiment, an adhesive (hot melt adhesive) can be applied to the hem.

[0081] After applying the tape / adhesive to the horizontal sealing area of the bag body 700, the folding process can be carried out to fold or turn over the horizontal sealing area so that the part coated with the tape / adhesive adheres to the main body (or core area) of the bag body. The sealed area is folded or turned over above or below the bag body to maximize the effective heat insulation coverage area. In addition, when high temperature and / or high pressure are applied to the bag body in subsequent processes to degas and compact the contents, the folded or turned-over seal will press more firmly against the main body of the bag body, making the sealed side or edge of the bag body less susceptible to the risk of cracking and filler leakage.

[0082] As Figure 8a In one embodiment shown in -b, the top and bottom seals (only one seal 870 is shown in the figure) are folded or turned over towards the main surface 830 of the main body 850 of the bag body 800, regardless of whether there are pre-folded corners. An adhesive or tape can be provided between the sealed hem and the main surface 830 (or 890) of the bag body to make the hem adhere to the main body 850 (or core part) of the bag body. Preferably, both the top and bottom sealed hems are folded / turned over onto the same main surface 830 or 890 of the main body 850 of the bag body. Alternatively, the top and bottom sealed hems are respectively folded / turned over onto the opposite main surfaces 830 and 890 of the main body 850 of the bag body. Folding helps prevent the hem from obstructing the assembly of the bag body in other products (such as the battery of an electric vehicle). Folding also creates an obstacle to the powder at the fold line of the hem, helping to prevent powder leakage from the sealed hem in case the seal is not properly sealed, or the seal condition deteriorates due to wear, poor storage, or long time, and the sealing performance decreases.

[0083] Examples of fully folded or turned-over bag bodies can be seen in Figure 15 、 Figure 15a 、 Figure 15b and Figure 15c . Now the drawings will be described. Note that these drawings are not drawn to scale, and the thickness of the hem in the side view is enlarged for clearer display.

[0084] Figure 15 Shows the rear view of the folded bag body 1500 Figure 15 A, front view Figure 15 B and side view Figure 15C. The folded bag body 1500 has a first folded horizontal seal 1502 (or folded top seal), a second folded horizontal seal 1506 (or folded bottom seal), and a folded longitudinal seal 1504 (or folded center seal) perpendicular to the first folded horizontal seal 1502 and the second folded horizontal seal 1506. The folded longitudinal seal 1504 can be folded first. The first folded horizontal seal 1502 and the second folded horizontal seal 1506 can be folded subsequently. In Figure 15 the example of Figure 15 A, all the folded seals 1502, 1504, and 1506 are visible in the rear view Figure 15 In terms of the left edge of the folded bag body 1500.

[0085] Figure 15a The rear view of the folded bag body 1510 is shown Figure 15 D, the front view Figure 15 E, and the side view Figure 15 F. The folded bag body 1510 has a first folded horizontal seal 1512 (or folded top seal), a second folded horizontal seal 1516 (or folded bottom seal), and a folded longitudinal seal 1514 (or folded center seal) perpendicular to the first folded horizontal seal 1512 and the second folded horizontal seal 1516. The folded longitudinal seal 1514 can be folded first. The first folded horizontal seal 1512 and the second folded horizontal seal 1516 can be folded subsequently. In Figure 15a the example of Figure 15 D, all the folded seals 1512, 1514, and 1516 are visible. The folded longitudinal seal 1514 is located in the central area of the folded bag body 1510.

[0086] Figure 15b The rear view of the folded bag body 1520 is shown Figure 15 G, the front view Figure 15 H, and the side view Figure 15 I. The folded bag body 1520 has a first folded horizontal seal 1522 (or folded top seal), a second folded horizontal seal 1526 (or folded bottom seal), and a folded longitudinal seal 1524 (or folded center seal) perpendicular to the first folded horizontal seal 1522 and the second folded horizontal seal 1526. The folded longitudinal seal 1524 can be folded first. The first folded horizontal seal 1522 and the second folded horizontal seal 1526 can be folded subsequently. In Figure 15b the example of Figure 15 G, the folded seal 1524 is visible, and the folded seals 1522 and 1526 are visible in the front view Figure 15 H. The folded longitudinal seal 1524 is located in the central area of the folded bag body 1520.

[0087] Figure 15c Shows the rear view of the folded bag body 1530 Figure 15 J, front view Figure 15 K and side view Figure 15 L. The folded bag body 1530 has a first folded horizontal seal 1532 (or folded top seal), a second folded horizontal seal 1536 (or folded bottom seal), and a folded longitudinal seal 1534 (or folded center seal) perpendicular to the first folded horizontal seal 1532 and the second folded horizontal seal 1536. The folded longitudinal seal 1534 can be folded first. The first folded horizontal seal 1532 and the second folded horizontal seal 1536 can be folded subsequently. In Figure 15c the example of, all the folded seals 1532, 1534 and 1536 are visible in the rear view Figure 15 J. In Figure 15c the example of, the folded seal 1534 is visible in the rear view Figure 15 J, and the folded seals 1532 and 1536 are visible in the front view 25K. The folded longitudinal seal 1534 is located at the edge of the folded bag body 2530 (in terms of Figure 15c , at the right edge of the folded bag body 1530). In another embodiment, the folded longitudinal seal 1534 can be located at the edge 1538 of the folded bag body 1530 (in terms of Figure 15c , at the left edge of the folded bag body 1530).

[0088] As Figure 15 , Figure 15a , Figure 15b and Figure 15c shown, by folding the seal flange above or below the core area of the bag body, the effective heat insulation coverage area of the heat insulation device can be maximized. In addition, when high temperature and high pressure act on the top and bottom of the bag body, the seal flange can be more firmly pressed against the core area of the bag body, thus being less susceptible to the risk of cracking and filler leakage. Other configurations of the seal flange folded above or below the core area of the bag body may also be applicable.

[0089] Figure 9a -d shows that the bag body can be provided with an adhesive / tape on one of its main surfaces (front or back). Therefore, the bag body can be adhered to a surface according to its application requirements. If the bag body is not immediately assembled into other components (such as an electric vehicle battery), a release paper can be provided on the adhesive / tape. A release liner or release paper is basically a paper- or plastic-based sheet used to prevent premature adhesion of a sticky surface. Labels can also be added to the bag body / heat insulation device. An inkjet printer or a laser marking system can be used to add labels. The labels can contain product information (such as model number, batch number, etc.) and / or production date.

[0090] The adhesive can be in liquid form and sprayed onto the main surface of the heat insulation device. Alternatively, a double-sided tape or a substrate-free tape with a release paper on one side can be pasted onto the main surface (front and back) of the heat insulation device. The heat insulation device can have tape / adhesive and release paper on one or both of its main surfaces.

[0091] Specifically, a tape pasting process can be used to apply the adhesive onto the heat insulation device. In the adhesive application, the adhesive is prepared and applied onto the target surface of the heat insulation device. Subsequently, the release paper is pasted onto the applied adhesive. In another embodiment, a single-sided tape with a release paper on one side can be used. In this case, the adhesive is first applied onto the target surface of the heat insulation device, and then the side of the single-sided tape without the release paper is pasted onto the applied adhesive. For a double-sided tape or a substrate-free tape with a double-sided release paper, first remove the release paper on one side of such a tape so as to paste the tape onto the target surface of the heat insulation device. The tape can be cut into the required size before or after (preferably before) adhering to the target surface of the heat insulation device.

[0092] Figure 9a -d shows different scenarios 908, 910, 912, and 914 of the application of the tape on one or both main surfaces / sides of the heat insulation device. The actual situation depends on the application and can be any of the above scenarios. For example, in the case of scenario 908, the tape or adhesive 908a is applied onto the entire main surface of the heat insulation device. In the case of scenario 910, the tape or adhesive 910a is applied onto a specific surface area of the heat insulation device. In the case of scenario 912, the tape or adhesive 912a is applied onto a surface area that varies with the width of the heat insulation device. That is, the surface area where the tape or adhesive is applied is a function of the width. For example, this surface area can maintain the same distance from the width boundary ends of the heat insulation device. This surface area can extend substantially along the length direction of the heat insulation device. The width boundary ends refer to the two ends that are opposite in position and separated by the width distance of the heat insulation device. In the case of scenario 914, the tape or adhesive 914a is applied onto a surface area that varies with the length of the heat insulation device. That is, the surface area where the tape or adhesive is applied is a function of the length. For example, this surface area can maintain the same distance from the length boundary ends of the heat insulation device. The length boundary ends refer to the two ends that are opposite in position and separated by the length distance of the heat insulation device. In addition, multiple other tapes or adhesives 914b covering a specific surface area can be applied at specific positions. In this case, the size of the tape or adhesive 914b is relatively smaller than that of the tape or adhesive 914a. The tapes or adhesives 908a, 910a, 912a, 914a, and 914b used should be equipped with peelable release papers so that they can adhere to the surface as needed.

[0093] Figure 10a-c shows four products (or compositions or devices) 1010, 1020, 1030, and 1000. An intumescent (flame retardant) sheet 1012 (described later) can be adhered or placed on one or more major surfaces of the thermal insulation device 1008. Instead of the intumescent sheet 1012, an intumescent coating (also labeled 1012) can be applied to one or more major surfaces of the thermal insulation device 1008. Examples of such intumescent coatings include flame retardant paints and impregnating solutions that can be used to fabricate a flame retardant device as described below.

[0094] In Figure 10a product 1010 includes the thermal insulation device 1008 and two layers of intumescent sheets or coatings 1012 disposed on two major surfaces of the thermal insulation device 1008.

[0095] In Figure 10b product 1020 includes two thermal insulation devices 1008, respectively disposed on two major surfaces of a layer of intumescent sheet 1012. The intumescent sheet 1012 in product 1020 can also be an intumescent coating (also labeled 1012). Product 1030 includes the thermal insulation device 1008 disposed on one major surface of a layer of intumescent sheet 1012.

[0096] In Figure 10c product 1000 includes the thermal insulation device 1008 and two flame retardant devices 1002 disposed on two major surfaces of the thermal insulation device 1008. An adhesive in the form of a tape or coating film (such as the adhesive film 1014) can be used to adhere the two flame retardant devices 1002 to the thermal insulation device 1008. The flame retardant device is not necessarily intumescent. However, the flame retardant device 1002 is preferably an intumescent sheet, such as the flame retardant device described below.

[0097] Figure 10a The products 1000, 1010, 1020, and 1030 shown in -c can be used with or without the frame structure described below.

[0098] In the present disclosure, the flame retardant device refers to an intumescent sheet suitable for, but not limited to, thermal runaway management of electric vehicle batteries. The thickness of the sheet is less than 2 mm, preferably less than or equal to 1 mm. For example, the intumescent sheet is made by impregnating non-woven inorganic fibers in an alkali metal silicate-based solution (referred to as the "impregnating solution" in the present disclosure). The impregnating solution can be an aqueous intumescent coating containing aerogel. The impregnating solution can contain additives, and after drying and / or curing, the intumescent sheet has an alkali metal silicate-based coating containing the additives. Such a flame retardant device is Figure 10c the flame retardant device 1002 in Figure 10a The intumescent sheet 1012 in -b can also be such a flame retardant device. "Flame retardant device" in this specification all refers to the described flame retardant device.

[0099] The composition of the expanded sheet (after drying) and the composition of the impregnating solution for an example of a flame retardant device are described below.

[0100] The expanded sheet may include a nonwoven inorganic fiber mat (or fabric), such as ECR-50 (a type of E-glass) produced by Owens Corning. The impregnating solution used for this product contains a sodium silicate-based binder and fine aerogel particles having hydrophobic surface groups. The aerogel particles have a particle size of 10 - 60 μm and a porosity of over 90%. Alumina (a metal oxide) and metal dihydroxide (a metal hydroxide) are added as additives to the impregnating solution to improve the mechanical strength, heat insulation, and flame retardant properties of the char layer.

[0101] Table 2a and 2b below show examples of the composition of the flame retardant device after drying and the composition of the impregnating solution. Table 3 below shows the selected properties of the expanded sheet.

[0102] Table 2a: Composition of the expanded sheet (after drying)

[0103]

[0104] Table 2b: Composition of the impregnating solution

[0105]

[0106] Table 3: Selected properties of the expanded sheet.

[0107]

[0108]

[0109] A surfactant with a pH value stabilized within the range of 2 to 12 can be added to the impregnating solution to improve its ability to spread and wet the nonwoven inorganic fiber mat. Preferably, the surfactant is selected from the group consisting of amine oxides, alkyl carbohydrate esters, alkoxylated polysiloxanes, and alkyl acrylates. The filling amount of the surfactant can be 0.2 to 0.5 wt% of the impregnating solution, and the preferred filling amount is 0.2 to 1.2 wt% of the expanded sheet.

[0110] Regarding the nonwoven inorganic fiber mat of the flame retardant device, in addition to E-type glass, S-type glass is also a preferred option. If E-type glass is used, the most preferred is E-type glass with the boron oxide component removed. The diameter and length of the fibers should be between 10 - 15 μm and 15 - 60 mm, respectively.

[0111] Other additives that impart heat insulation properties (i.e., additives that can form a dense grid carbonized layer), which are microporous, such as fumed silica and hollow glass microspheres, can also be used. Other suitable ceramic additives that enhance the strength of the carbonized layer, such as combinations of metal oxides, metal hydroxides, metal carbonates, metal silicates, and / or metal powders, can also be used.

[0112] In addition to the above components, optionally, 1 to 10 wt% of a light-shielding agent, such as iron oxide, silicon carbide, and / or titanium dioxide, is added to the expanded sheet. The light-shielding agent provides high-temperature heat insulation and is used for reflection to reduce radiative heat transfer at high temperatures.

[0113] An organic additive can be added at the impregnation station (i.e., the location where the nonwoven inorganic fiber mat and the impregnation solution are impregnated) to enhance the flexibility and water resistance of the expanded sheet. Glycerol and polyvinyl alcohol are preferred examples of organic additives.

[0114] The production of the impregnation solution involves: sequentially adding an alkali metal silicate solution and one or more surfactants, then adding a heat-insulation imparting agent, a carbonized layer strength enhancer, and other additives, and finally adding the required amount of water; after each addition (i.e., after each addition of a component), stirring and mixing for 15 minutes, and continuing to stir and mix the solution with all the added components for 2 - 3 hours. The hardening agent is the last component added to the impregnation solution and is added just before impregnating the nonwoven inorganic fiber mat. The viscosity is preferably 200 - 500 centipoises (cps).

[0115] The hardening agent is preferably sodium fluorosilicate or potassium methyl silicate (most preferably).

[0116] If a light-shielding agent, a hardening agent, and water are added, the composition of the impregnation solution is as shown in Table 4 below.

[0117] Table 4: Composition of the impregnation solution (variant of the product in Table 2b above)

[0118]

[0119]

[0120] To prepare the expanded sheet, first, stack the nonwoven inorganic fiber mat on a non-sticky polymer sheet and impregnate it with an aqueous alkali metal silicate-based solution (i.e., the impregnation solution).

[0121] Various impregnation methods can be used, such as spraying, brushing, and / or doctor-blading. Preferably, the doctor-blading method is used to achieve better thickness control and the feasibility of large-scale production. Subsequently, dry at a suitable temperature (e.g., room temperature) to remove moisture and avoid defects such as warping. Optionally, curing can be carried out at a higher temperature (e.g., by microwave heating) to accelerate the process.

[0122] Other additives that can be added to enhance the strength of the carbon layer include zirconia and colloidal silica. Sodium silicate is defined by the molar ratio of silica to sodium oxide. Increasing the proportion of silica forms a stronger carbon layer, while adding colloidal silica can adjust the degree of enhancement.

[0123] An example of a flame retardant device can have the following expansion characteristics, for example, it can react quickly at a temperature > 175 °C, expand to 5 times its original thickness, forming a heat-insulating foam that fills voids and reduces heat transfer. The material is non-combustible and has an inorganic formulation. An example of a flame retardant device can be a flexible sheet, manufactured in large rolls for lamination and die-cutting. The nominal thickness of the flame retardant device can be from 0.4 mm to 1.0 mm. See the present embodiment of the flame retardant device shown in Tables 4a and 4b below.

[0124] Table 4a: Typical characteristics

[0125]

[0126] Table 4b: Product series

[0127]

[0128] Figure 11a -b shows an example of the steps for forming and sealing the bag of the heat insulation device 1100. In this embodiment, the bag of the heat insulation device 1100 is sealed in a three-sided sealing manner and has three sealing areas 1170. It should be understood that in another embodiment, a four-sided sealed bag can also be used if needed. These three sealing areas 1170 include the first and second horizontal sealing areas, which have the same length as the width of the bag 1100 and are located on the opposite side edges of the bag 1100. The third central seal is orthogonal to the first and second horizontal sealing areas.

[0129] First, the heat insulation device 1100 is inserted into the main opening 1140 of a one-piece frame structure 1180 (such as a silicone frame) to form a framed heat insulation device 1185. Secondly, an electrically insulating film layer 1190 is added or arranged in whole or in part on the main surface of the framed heat insulation device 1185. Heat and pressure are applied to these film layers 1190 to soften and / or melt them to form a seal.

[0130] The framed heat insulation device can also include a combination of a heat insulation device and a flame retardant device. If the above-mentioned forming and sealing process is used to manufacture a framed and sealed heat insulation device and a flame retardant device, the heat insulation device 1100 can be replaced with, for example, a heat insulation device that adheres two layers of flame retardant device layers. Other combined configurations of the heat insulation device and the flame retardant device may also be applicable.

[0131] Figure 12a -b shows a first example of the framed heat insulation device 1200.Figure 12a Top view 12A of the framed thermal insulation device 1200 Figure 12b Figure 12B is a cross-sectional view thereof. The framed thermal insulation device 1200 includes a thermal insulation device 1208 and two layers of flame retardant (FR) devices 1202. Each layer of the flame retardant device 1202 is disposed on each side of the main surface of the thermal insulation device. The thermal insulation device 1208 is sandwiched between two layers of the flame retardant devices 1202. A frame structure 1204 composed of a top and a bottom frame layer is provided to cover the sides or edges along the outer edge of the thermal insulation device 1208. A sealing layer 1206 is disposed above each main surface of the framed thermal insulation device 1200. The seal 1206 forms an external protective layer above the exposed main surfaces of the two layers of the flame retardant devices 1202.

[0132] Figure 13a -b shows another example of the framed thermal insulation device 1300. Figure 13a Top view 13A of the framed thermal insulation device 1300 Figure 13b Figure 13B is a cross-sectional view thereof. The framed thermal insulation device 1300 includes a thermal insulation device 1308, wherein the sides or edges along the outer edge of the thermal insulation device 1308 are sandwiched in a frame structure 1304 composed of a top and a bottom frame layer. A sealing layer 1306 is disposed above each main surface of the framed thermal insulation device 1300. The seal 1306 forms an external protective layer above the exposed main surface of the thermal insulation device 1308.

[0133] Table 5a below shows an example of the specifications of the frame structure with two layers of frame layers.

[0134] Table 5a: Example of Frame Specifications

[0135] Frame material: For example, silicone or other similar or suitable materials Frame size: 148 x 98 mm Frame width: ~5–6 mm Frame thickness: 1.5 mm for each frame Frame adhesive: For example, a refractory adhesive (for adhesion to the thermal insulation device or its combination)

[0136] Table 5b below provides examples of the size ranges and weight ranges of framed thermal insulation devices with / without frames and with / without flame retardant devices and their combinations for electric vehicle battery applications.

[0137] Table 5b:

[0138]

[0139] Figure 14 Shows Figure 13a Top view 13A in Figure 13b Cross-sectional view 13B in, and Figure 12b An enlarged view of cross-sectional view 12B in Figure 14Specific examples of possible dimensions of a first example of a frame-type heat insulation device 1200 and a second example of a frame-type heat insulation device 1300 are shown. The length and width of the frame-type heat insulation device 1300 may be approximately 148 mm and 98 mm, respectively. The frame-type heat insulation device 1200 (the top view 12A is not shown in Figure 14 ), may also have the same length and width. The thickness (excluding the seal) of the frame-type heat insulation device 1200 and the frame-type heat insulation device 1300 is approximately 3 mm. The thickness of each layer of the two-layer frame structure 1204 in the frame-type heat insulation device 1200 and the frame-type heat insulation device 1300 may be approximately 1.5 mm. The thickness of the heat insulation device 1308 in the frame-type heat insulation device 1300 may be 2 mm. The thickness of each layer of the two-layer flame retardant device 1202 in the frame-type heat insulation device 1200 may be approximately 0.5 mm. The thickness of the heat insulation device 1208 in the frame-type heat insulation device 1200 may be 2 mm.

[0140] An example of a manufacturing process of the heat insulation device is described as follows.

[0141] In step (1), the raw materials are received and inspected to ensure that the correct materials and quantities are received.

[0142] In step (2), the raw materials are stored in the raw material warehouse.

[0143] In step (3), the powders required to prepare the mixed powder (i.e., the final powder that fills each bag of the heat insulation device) are unpacked and placed in one or more mixing buffer devices. A buffer device refers to a container or storage device for containing or storing powders. The buffer device may be a hopper. Each mixing buffer device can hold different types of powders. For example, one of the mixing buffer devices can hold fine particles of silica aerogel, while another mixing buffer device can hold metal oxide (light-shielding agent) powder. If other materials need to be added, another additional mixing buffer device can hold these materials. The mixing buffer device may be a bowl-shaped or funnel-shaped component with a wide receiving area and a depth or height sufficient to hold the powder.

[0144] In step (4), the powders are metered or dispensed from one or more mixing buffer devices into the mixer in the correct dosage.

[0145] In step (5), the mixer mixes the powders metered or dispensed into the mixer. A stirrer or other suitable equipment can be set up to uniformly mix the dispensed powders.

[0146] In step (6), the mixing quality is checked. For example, computer vision or X-ray can be used to detect whether the mixed powder is sufficiently homogeneous.

[0147] In step (7), the mixed powder that has passed the quality inspection is dispensed or conveyed to a mixed powder buffer device or a storage device.

[0148] In step (8), the mixed powder obtained in step (7) is conveyed or poured into a hopper to fill the powder into the bag body. The hopper is connected to the equipment or machine for supplying the mixed powder to the equipment.

[0149] In step (9), the equipment performs the following steps: forming of the film and / or the bag body, metering of the powder, filling of the formed bag body, sealing of the bag body, and cutting of the filled bag body into individual bag body sizes. For example, a vertical or horizontal form, fill, and seal machine can be used. After step (9), the equipment forms a bag body filled with the mixed powder. Each bag body can be made from one or more rolls of film, which are fed into the equipment to form the bag body. A film can be perforated and packaged as a roll of film. Each film can include multiple layers. For example, the film material layers FML1 and / or FML2 and / or FML3 can form the above-mentioned multiple layers. In one embodiment, the film material for forming the bag body is prefabricated and provided in the form of wholesale rolls for bag body forming. The perforations should be small enough to prevent the powder from leaking through the perforations.

[0150] In step (10), a quality inspection of the filling process is carried out. It is completed by weight inspection. Each bag is weighed to check if it meets the preset weight requirement. Bags that do not meet the weight requirement will be rejected and stored in a non-conforming product container. Depending on the status of the non-conforming products, each product can be re-inspected for weight or re-filled. Qualified bag bodies or bag bodies that have passed the quality inspection will be conveyed to the next station for subsequent processing. If a square or rectangular bag body needs to be formed, at the end of step (10), the formed bag body will have 3 to 4 flanged sides due to the side sealing implemented by the equipment in step (9).

[0151] In step (11), a first cleaning step is carried out to clean each bag body that has passed the quality inspection in step (10). After cleaning, an optional quality inspection of the cleanliness of each bag body is carried out. Air blowing can be used for cleaning, that is, blowing air into the bag body to clean the bag body, and / or applying vacuum suction to the bag body to suck out the powder (if any) on the bag body, and / or using other suitable cleaning methods. The first cleaning step is useful in cases where, for example, the powder leaks (or spills) at the hopper or the equipment, or the bag body ruptures or leaks in step (9) or (10). Step (11) is an optional but recommended step.

[0152] In step (12), a pre-fold is carried out. Such a pre-fold refers to folding or bending each corner of each bag body. For a square or rectangular bag body, each corner refers to each of the four sharp corners. This is to ensure that there is no leakage at the corners of each bag. Step (12) is an optional but recommended step.

[0153] In step (13), after completing or skipping the pre-fold, an adhesive or tape is applied to the hem of the bag body to prepare for the subsequent folding or turning of the hem and pasting it to the bag body main body.

[0154] In step (14), each bag body hem is folded or turned so that it is pasted onto the bag body main body. This folding step helps prevent the hem from obstructing the assembly of the bag body in other products (such as the battery of an electric vehicle). The folding also creates an obstruction to the powder at the fold line of the hem, helping to prevent powder leakage from the sealed hem in cases where the seal is not properly sealed, or the seal condition deteriorates due to wear, poor storage, or long time, and the seal performance decreases.

[0155] In step (15), a quality inspection of the folding is carried out. Computer vision technology can be used for this inspection.

[0156] In step (16), each bag body is leveled to evenly distribute the powder inside the bag body. For example, this can be achieved by vibration. This step can be implemented independently before degassing, or in combination with the following degassing process.

[0157] In step (17), each folded bag body is transported to a station for 1) degassing, 2) heating, and 3) cooling of the bag body. These three steps can be implemented in the following manner. During degassing, the bag body is compressed to expel air from the bag body. Degassing and compression can help compact the functional filler inside the bag body. This degassing process involves applying pressure to the main surface of the bag body to flatten the bag body. Since the film layer of the bag body contains micropores, the gas is released through these micropores. After or during the application of pressure, the bag body is heated, and during heating, for example, the film layer softens to form the bag body, which helps release more gas from the bag body. After heating, the bag body is cooled. The cooling can be active cooling, where the temperature is actively reduced to rapidly cool the bag body. Or, the cooling can also be carried out in a natural way. Preferably, the bag body is under pressure during all three steps.

[0158] In step (18), a second cleaning step is carried out to clean each bag body that has been degassed in step (17). An optional cleaning quality inspection can also be carried out after cleaning. Air blowing can be used for cleaning, that is, blowing air onto the bag body to clean the bag body, and / or applying vacuum suction to suck off the powder (if any) on the bag body, and / or using other suitable cleaning methods. The second cleaning step is useful, for example, in cases where powder leaks (or spills) from the bag body, or the bag body ruptures in step (16). Step (18) is an optional but recommended step.

[0159] In step (19), an optional but recommended end-of-line inspection (quality check) should be performed on each bag. Through computer vision technology or other suitable methods, the weight, size, appearance, wrinkle flatness, powder leakage, and / or thickness of the bag are inspected to ensure that the quality requirements are met. After the inspection, an optional step of adding labels or marks to the bag can be carried out. In this step of adding labels or marks, for example, an inkjet or laser printer can be used to label manufacturing information and / or product details on the outer film layer of each bag.

[0160] In step (20), an optional taping step can be performed on the bag to apply tape to the bag so that the bag can adhere to a surface according to the application requirements of the bag. If the bag is not immediately assembled into other components (such as an electric vehicle battery), a release liner can be provided on the tape. A release liner or release paper is basically a paper- or plastic-based sheet used to prevent premature adhesion of a sticky surface.

[0161] In step (21), the quality of the taping operation performed in step (20) is inspected to ensure that the taping and / or release liner attachment operations are correct. Computer vision technology can be used for this inspection.

[0162] In step (22), the bag is packaged and prepared for delivery. For example, the bags can be stacked and bundled into bales first, and then the bales are packed into cardboard boxes.

[0163] In step (23), the cardboard boxes containing the bags are stacked on a shipping pallet.

[0164] In step (24), the shipping pallet is transferred to the pre-shipment warehouse for preparation for delivery.

[0165] Generally speaking, the key processes of the above manufacturing process are bag forming, powder filling and bagging, folding of the sealed sides of the bag, degassing, and heat treatment.

[0166] An example of a method for manufacturing a frame-type heat insulation device and its combination is described below. It may include step (A) bag preparation and filling, step (B) frame forming, step (C) degassing, step (D) placement of a flame retardant device, and step (E) sealing. The frame-type heat insulation device includes a heat insulation device in a bag-like structure filled with the aforementioned functional filler.

[0167] Step (A) Bag preparation and filling can adopt the aforementioned steps (1) to (15) (which may or may not include the steps described as optional in the foregoing). The output of step (A) can be a bag body of the thermal insulation device that has not been degassed, heat-treated, and cooled. Alternatively, the output of step (A) can be a bag body made through steps (1) to (24) (i.e., a bag body that has been completed in degassing, heat-treatment, and cooling).

[0168] Step (B) Frame forming receives the output from step (A). The output of step (B) is a framed thermal insulation device. Taking a frame structure with 2 components or 2 frame layers as an example, a pick-and-place robot, such as a six-axis robot, can be used during frame assembly. In the first step, the bottom frame is placed on a platform or fixture. In the second step, one or more bag bodies of the thermal insulation device are placed on the bottom frame. In the third step, the top frame is placed above the thermal insulation device. After the third step, the thermal insulation device will be clamped between the top frame and the bottom frame. To bond the thermal insulation device to the top frame and the bottom frame, an intermediate bonding step is provided between the first step, the second step, and the third step. Adhesives can be used for bonding. The adhesive can be in the form of a tape, such as a double-sided tape or a tape without a substrate. In the first case, the top frame is bonded to the bottom frame; in the second case, the top frame is bonded to the bag body and the bottom frame is bonded to the bag body. The second case can be applied if the bag body is thick and the top frame cannot contact the bottom frame when placed on the bag. Although a frame structure with 2 frame layers has been described, the current process can also adopt a one-piece frame structure.

[0169] Step (C) Degassing can be implemented through a degassing conveying device / system. This degassing conveying system can heat-treat the bag body with a frame or not. If the bag body has not been degassed or has been insufficiently degassed before, the purpose of degassing is to remove the excess air in each bag body of the thermal insulation device. Degassing also helps to fix the frame structure of each bag body (i.e., fixing the two frame layers together, or fixing them on the two frame layers). An example of the degassing conveying device / system includes a top conveyor and a bottom conveyor. The top (upper) conveyor belt includes a plurality of interconnected top plates that continuously move in a cycle; the bottom (lower) conveyor belt includes a plurality of interconnected bottom plates that continuously move in a cycle. Each top plate cooperates with the bottom plate to compress the bag body with a frame of the thermal insulation device placed between the two plates, so as to degas the bag body with a frame. The distance between the top plate and the bottom plate can be adjusted to apply or release pressure on the bag body with a frame.

[0170] Each top plate and / or bottom plate may be configured to facilitate degassing of each bag through vacuum suction. The surface of the top plate and / or bottom plate in contact with the framed bag may be provided with a plurality of perforations and connected to a vacuum suction unit to suction air through these perforations. Vacuum suction will be used to degas the bag when the perforated surface of the top or bottom plate contacts the framed bag.

[0171] Before or after degassing, step (D) of inserting a fire retardant device may be performed to load one or more fire retardant devices into the framed thermal insulation device. The input of this process is a framed thermal insulation device with an opening defined by a frame layer and exposing the thermal insulation device. Each frame layer covers the outer edge of the thermal insulation device and has a hollow center corresponding to the above-mentioned opening. In the first step, a first fire retardant device is inserted into a first opening in the top or bottom frame layer. The first fire retardant device will contact the thermal insulation device after being embedded. In the second step, the top or bottom main surface of the framed thermal insulation device is sealed to fix the first fire retardant device in the first opening. In the third step, the framed thermal insulation device is flipped. In the fourth step, a second fire retardant device is respectively embedded into a second opening in the bottom or top frame layer. The second fire retardant device will contact the thermal insulation device after being embedded. In the fifth step, the corresponding bottom or top surface of the framed thermal insulation device is sealed to fix the second fire retardant device in the second opening. The specific details of the sealing process will be described below.

[0172] Step (E) involves sealing the framed thermal insulation device, preferably immediately after inserting the fire retardant device into the framed thermal insulation device. After inserting the first fire retardant device, the outer main surface of the framed thermal insulation device with the inserted first fire retardant device is sealed, and then the framed thermal insulation device is flipped to insert the second fire retardant device. A sealing layer is applied to the framed thermal insulation device containing the inserted first fire retardant device. After flipping the framed thermal insulation device and inserting the second fire retardant device, another layer of sealing layer is applied to the outer main surface of the framed thermal insulation device with the inserted second fire retardant device. The finally sealed and framed thermal insulation device contains a thermal insulation device between two fire retardant devices and two frame layers, and the two main surfaces of the thermal insulation device are sealed. A label (or sealing) applicator is a device that can be used to apply the seal. The seal can be a coating or film of a suitable plastic material (such as a polymer sheet). In another embodiment, an electric current is passed through the film layer of the sealing material to heat it, soften and / or melt it, thereby forming a seal that can adhere to the outer main surface of the framed thermal insulation device.

[0173] Embodiments of the present disclosure may have the following features. (The reference numerals in parentheses refer to the numbers of the corresponding elements in the figures)

[0174] A heat insulation device (such as 100, 200, 500, 600, 1010, 1020, 1030, 1000, 1200, 1300, 1500, 1510, 1520, 1530), comprising:

[0175] Functional fillers (such as FF1, FF2 and / or FF3) encapsulated in a bag, wherein the bag is made of a film material (such as a combination of FF4, FML1 to FML3; 300a, 300b, 400), and the film material comprises:

[0176] An inorganic fiber layer (such as FML2 102); and

[0177] A polymer layer (such as FML3 103),

[0178] wherein the inorganic fiber layer is laminated on the polymer layer,

[0179] wherein the bag comprises a sealed side formed by sealing the film material,

[0180] the functional fillers are encapsulated in the bag so that the functional fillers do not escape from the sealed side of the bag, and

[0181] the functional fillers comprise heat insulation particles in powder form (such as FF1). Referring to Table 1, it should be understood that other combinations of the inorganic fiber layer laminated on the polymer layer can be:

[0182] a) FML1, FML2 or FML3 as the polymer layer is in contact with FF4 as the inorganic fiber layer;

[0183] b) FML1 or FML2 as the inorganic fiber layer is in contact with FML2 or FML1 as the inorganic fiber layer;

[0184] c) FML1 as the inorganic fiber layer is in contact with FML3 as the polymer layer (in this case, FML2 does not exist), etc.

[0185] Note that "laminated on" can mean that the inorganic fiber layer is above the polymer layer, or the polymer layer is above the inorganic fiber layer.

[0186] The film material (such as 300a) may comprise:

[0187] A cover layer (such as FML1, 201, 301), the cover layer being laminated on the inorganic fiber layer so that the inorganic fiber layer is between the cover layer and the polymer layer,

[0188] Wherein the covering layer is a polycarbonate (PC) film, a polyimide (PI) film, a polyethylene terephthalate (PET) film, a cyclic olefin polymer (COP) film, a cast polypropylene (CPP) film or a nylon film.

[0189] The covering layer can be mixed with the inorganic fiber layer so that there is no obvious boundary between the inorganic fiber layer and the covering layer.

[0190] Alternatively, the film material may comprise:

[0191] A covering layer (such as FML1 101), the covering layer being laminated on the inorganic fiber layer so that the inorganic fiber layer is located between the covering layer and the polymer layer,

[0192] Wherein the covering layer is a woven ceramic fiber fabric.

[0193] The film material may comprise:

[0194] The innermost layer (such as FF4 114),

[0195] Wherein the polymer layer is laminated on the innermost layer,

[0196] Wherein the innermost layer is in contact with the functional filler and the innermost layer is made of:

[0197] At least one of glass fiber, quartz wool, mineral wool, ceramic fiber, woven fiber fabric and non-woven fiber fabric.

[0198] The innermost layer (such as FF4 114) can be an acrylic resin-bonded glass fiber base fabric.

[0199] The inorganic fiber layer can be woven.

[0200] The inorganic fiber layer can be a glass fiber woven fabric, and the glass fiber can be E glass fiber.

[0201] The polymer layer can be made of:

[0202] Polycarbonate (PC), polyethylene (PE), polypropylene (PP) or polyvinyl chloride (PVC); or

[0203] A composite material, comprising: PC, PE, PP and / or PVC; and a flame retardant.

[0204] The functional filler may comprise:

[0205] At least one of aerogel powder, fumed silica and glass microspheres; and

[0206] At least one of titanium dioxide (TiO2), iron oxide (Fe2O3), and aluminum oxide (Al2O3).

[0207] The functional filler may further comprise:

[0208] At least one of magnesium hydroxide (MDH), aluminum hydroxide (ATH), zinc borate, aluminum polyphosphate, and melamine cyanurate.

[0209] The polymer layer (such as 313) may be mixed with the inorganic fiber layer (such as 312) such that there is no clear boundary between the inorganic fiber layer and the polymer layer (such as 300b).

[0210] Two or more layers of the membrane material may be adhered to each other by an adhesive (such as 350).

[0211] The bag body (such as 600, 1100, 1170, 1500, 1510, 1520, 1530) may include only three sealed sides, the three sealed sides including a straight center seal (such as 660, 1504, 1514, 1524, 1534) and two straight side seals (such as 663, 665, 1502, 1506, 1512, 1516, 1522, 1526, 1532, 1536), wherein the straight center seal is orthogonal to the two straight side seals.

[0212] The bag body (such as 500) may include only four sealed sides (such as 570).

[0213] The corners of the bag body (such as 780) may be folded to prevent the functional filler from escaping from the corners. (For example Figure 7a -b shown pre-fold).

[0214] The sealed sides of the bag body (such as 700) may be folded and attached to the main body of the bag body to prevent the functional filler from escaping from the sealed sides of the bag body. (For example Figure 8a -b shown pre-fold)

[0215] The membrane material may include a plurality of perforations (such as 210, 410), wherein the perforations and the functional filler are sized such that the functional filler does not escape from the perforations.

[0216] The bag body may be degassed to compress the functional filler encapsulated within the bag body.

[0217] The heat insulation device (such as 1010, 1020, 1030) may include one or more intumescent flame retardant coatings applied to one or two main surfaces of the bag body.

[0218] The heat insulation device (such as 1000, 1200) may include one or more layers of expandable flame retardant sheets attached to one or two main surfaces of the bag body.

[0219] The heat insulation device (such as 1020) may include:

[0220] Two of the bag bodies; and

[0221] One or more layers of expandable flame retardant sheets disposed between the two bag bodies.

[0222] The expandable flame retardant sheet (such as the flame retardant device) may be a non-woven glass fiber felt coated or impregnated with a polymer or inorganic expandable solution.

[0223] The heat insulation device may include a frame structure (such as 1180, 1204, 1304) disposed along the outer edge of the heat insulation device.

[0224] The frame structure of the heat insulation device may be made of silicone.

[0225] The frame structure (such as 1204, 1304) may include:

[0226] A first frame layer attached to the first side of the heat insulation device; and

[0227] A second frame layer attached to the second side of the heat insulation device, the second side being opposite to the first side of the heat insulation device.

[0228] The frame structure may be a one-piece frame structure (such as 1180).

[0229] The heat insulation device may include one or more sheets of electrically insulating film material (such as 1206, 1306, 1190) for sealing one or more external main surfaces of the heat insulation device, respectively.

[0230] The heat insulation device may include tapes and / or adhesives (such as 908a, 910a, 912a, 914a and 914b) applied to one or more outer surfaces of the heat insulation device, and release paper is provided on the tapes and / or adhesives so that the heat insulation device can be adhered to another object as needed. Examples are Figure 9a -d in 908, 910, 912 and 914.

[0231] The functional filler may be non-matrix type. They are matrix-free, that is, there is no mesh formation, cross-linking with the binder, and / or structural reinforcement material in the functional filler. In this case, the functional filler is different from the aerogel blanket described in the background section of the present disclosure.

[0232] The battery may include the heat insulation device.

[0233] In this disclosure, unless the context clearly dictates otherwise, the term "comprising" has a non-exclusive meaning, indicating "including at least" rather than the exclusive meaning of "consisting only of". The same applies to other forms of this word, such as "comprise", "comprises", etc.

[0234] Although the present invention has been illustrated by several embodiments, implementations and embodiments, the present invention is not limited thereto, and it encompasses various obvious variations and equivalent solutions falling within the scope of the appended claims. Although the features of the present invention are expressed in specific combinations in the claims, it is contemplated that these features can be arranged in any combination and order.

Claims

1. A heat insulation device, comprising: Functional fillers encapsulated in a bag, wherein the bag is made of a film material, and the film material at least comprises: An inorganic fiber layer; and A polymer layer, wherein the inorganic fiber layer is laminated on the polymer layer, wherein the bag comprises a sealed side formed by sealing the film material, the functional fillers are encapsulated in the bag so that the functional fillers do not escape from the sealed side of the bag, and the functional fillers comprise heat insulation particles in powder form.

2. The heat insulation device according to claim 1, wherein the film material comprises: A covering layer laminated on the inorganic fiber layer, such that the inorganic fiber layer is located between the covering layer and the polymer layer, wherein the covering layer is a polycarbonate (PC) film, a polyimide (PI) film, a polyethylene terephthalate (PET) film, a cyclic olefin polymer (COP) film, a cast polypropylene (CPP) film or a nylon film.

3. The heat insulation device according to claim 2, wherein the covering layer is mixed with the inorganic fiber layer such that there is no obvious boundary between the inorganic fiber layer and the covering layer.

4. The heat insulation device according to claim 1, wherein the film material comprises: A covering layer laminated on the inorganic fiber layer, such that the inorganic fiber layer is located between the covering layer and the polymer layer, wherein the covering layer is a woven inorganic fiber fabric.

5. The heat insulation device according to any one of the preceding claims, wherein the film material comprises: An innermost layer, wherein the polymer layer is laminated on the innermost layer, wherein the innermost layer is in contact with the functional fillers, and the innermost layer is made of at least one of glass fiber, quartz wool, mineral wool, ceramic wool, woven fiber fabric and non-woven fiber fabric.

6. The heat insulation device according to claim 5, wherein the innermost layer is a glass fiber base fabric bonded with acrylic resin.

7. The heat insulation device according to any one of the preceding claims, wherein the inorganic fiber layer is woven.

8. The heat insulation device according to claim 7, wherein the inorganic fiber layer is a glass fiber woven fabric, and the glass fiber is E-glass fiber.

9. The heat insulation device according to any one of the preceding claims, wherein the polymer layer is made of: Polycarbonate (PC), polyethylene (PE), polypropylene (PP) or polyvinyl chloride (PVC); or A composite material, comprising: PC, PE, PP and / or PVC; and a flame retardant.

10. The heat insulation device according to any one of the preceding claims, wherein the functional fillers comprise: At least one of aerogel powder, fumed silica and glass microspheres; and At least one of titanium dioxide (TiO2), iron oxide (Fe2O3) and aluminum oxide (Al2O3).

11. The heat insulation device according to claim 10, wherein the functional fillers further comprise: At least one of magnesium hydroxide (MDH), aluminum hydroxide (ATH), zinc borate, aluminum polyphosphate and melamine cyanurate.

12. The heat insulation device according to any one of the preceding claims, wherein the polymer layer is mixed with the inorganic fiber layer such that there is no distinct boundary between the inorganic fiber layer and the polymer layer.

13. The heat insulation device according to any one of claims 1 to 11, wherein two or more layers of the film material are adhered to each other by an adhesive.

14. The heat insulation device according to any one of the preceding claims, wherein the bag body comprises only three sealed sides, the three sealed sides comprising a straight central seal and two straight side seals, wherein the straight central seal is orthogonal to the two straight side seals.

15. The heat insulation device according to any one of the preceding claims, wherein the bag body comprises only four sealed sides.

16. The heat insulation device according to any one of the preceding claims, wherein the corners of the bag body are folded to prevent the heat insulating particles from escaping from the corners.

17. The heat insulation device according to any one of the preceding claims, wherein the sealed sides of the bag body are folded and attached to the main body of the bag body to prevent the functional filler from escaping from the sealed sides of the bag body.

18. The heat insulation device according to any one of the preceding claims, wherein the film material comprises a plurality of perforations, and the perforations and the functional filler are sized such that the functional filler does not escape through the perforations.

19. The heat insulation device according to any one of the preceding claims, wherein the bag body is degassed to compress the functional filler encapsulated within the bag body.

20. The heat insulation device according to any one of the preceding claims, the heat insulation device comprising one or more layers of intumescent flame retardant coatings applied to one or two main surfaces of the bag body.

21. The heat insulation device according to any one of the preceding claims, wherein the heat insulation device comprises one or more layers of intumescent flame retardant sheets attached to one or two main surfaces of the bag body.

22. The heat insulation device according to any one of the preceding claims, wherein the heat insulation device comprises: two of the bag bodies; and one or more layers of intumescent flame retardant sheets disposed between the two bag bodies.

23. The heat insulation device according to claim 21 or 22, wherein the intumescent flame retardant sheet is a non-woven glass fiber mat coated or impregnated with a polymer or inorganic intumescent solution.

24. The heat insulation device according to any one of the preceding claims, wherein the heat insulation device comprises a frame structure disposed along the outer edge of the heat insulation device.

25. The heat insulation device according to claim 24, wherein the frame structure is made of silicone.

26. The heat insulation device according to claim 24 or 25, wherein the frame structure comprises: a first frame layer attached to a first side of the heat insulation device; and a second frame layer attached to a second side of the heat insulation device, the second side being opposite to the first side of the heat insulation device.

27. The heat insulation device according to claim 24 or 25, wherein the frame structure is a one-piece frame structure.

28. The heat insulation device according to any one of claims 20 to 27, wherein the heat insulation device comprises one or more electrically insulating film materials respectively for sealing one or more outer main surfaces of the heat insulation device.

29. The heat insulation device according to any one of the preceding claims, wherein the heat insulation device comprises a tape and / or an adhesive applied to one or more outer surfaces of the heat insulation device, and a release paper is provided on the tape and / or the adhesive so that the heat insulation device can be adhered to another object as required.

30. The heat insulation device according to any one of the preceding claims, wherein the functional filler is non-matrix.

31. A battery comprising the heat insulation device according to any one of the preceding claims.

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