Heat insulation part, packaging method, battery pack and vehicle

Abstract

The invention provides a heat insulation piece which comprises a heat insulation core material, a heat insulation layer and a heat insulation layer. The membrane material wraps the outer side of the heat insulation core material to package the heat insulation core material, the membrane material is folded to the top surface from the bottom surface along the two side surfaces, and a first overlapping part is formed on the top surface; second overlapping parts are respectively formed on the two end surfaces of the membrane material, and each second overlapping part comprises a first overlapping layer, a second overlapping layer and a third overlapping layer which are stacked; the first overlapping layer is folded to the heat insulation core material from the side surface; the second overlapping layer is folded from the top surface to the end surface so as to be partially overlapped with the first overlapping layer; the third overlapping layer is folded from the bottom surface to the end surface so as to be at least partially overlapped with the second overlapping layer; the membrane material further comprises a first attaching part, and the first attaching part extends to the top face from the third overlapping layer and is attached to the corresponding part of the membrane material. The invention further provides a packaging method, a battery pack applying the heat insulation part and a vehicle.

Description

TECHNICAL FIELD

[0001] The present application relates to a thermal insulation piece, a packaging method of the thermal insulation piece, a battery pack using the thermal insulation piece, and a vehicle using the battery pack. BACKGROUND

[0002] The thermal insulation core material of the thermal insulation piece used in the battery of a new energy vehicle is usually aerogel felt, fiber felt or the like. However, the material of the thermal insulation core material (especially the aerogel felt) is fragile, and in order to prevent powder from falling off, it needs to be used after packaging. A common packaging method is to arrange the thermal insulation core material between two film materials, and to heat-press and bond the periphery of the two film materials, so as to package the aerogel felt. However, this packaging method will cause the film material to form a sealing edge around the periphery of the aerogel felt, so that the proportion of the aerogel felt is reduced, and a thermal bridge will be formed at the sealing edge, which affects the thermal insulation effect. SUMMARY

[0003] The first aspect of the present application provides a thermal insulation piece, comprising:

[0004] a thermal insulation core material, the thermal insulation core material comprising a bottom surface and a top surface arranged oppositely, two side surfaces and two end surfaces arranged oppositely connected between the bottom surface and the top surface; and

[0005] a film material wrapped outside the thermal insulation core material to package the thermal insulation core material, the film material being folded from the bottom surface to the top surface along two side surfaces respectively, and at least partially overlapping on the top surface to form a first overlapping part;

[0006] wherein the film material further forms a second overlapping part on two end surfaces respectively, the second overlapping part comprising a first overlapping layer, a second overlapping layer and a third overlapping layer arranged in sequence; the first overlapping layer is folded from the side surface to the thermal insulation core material; the second overlapping layer is folded from the top surface to the end surface and at least partially covers the first overlapping layer; the third overlapping layer is folded from the bottom surface to the end surface and at least partially covers the second overlapping layer; the film material further forms a first bonding part, the first bonding part extends from the third overlapping layer to the top surface and is bonded with the film material located on the top surface.

[0007] The thermal insulation piece provided by the embodiment of the present application forms a first overlapping part on the top surface of the thermal insulation core material by arranging the film material, and forms a second overlapping part on two end surfaces of the thermal insulation core material, and the second overlapping part is bonded with the film material located on the top surface through the first bonding part connected with the third overlapping layer, so that the film material can package the thermal insulation core material along the external contour of the thermal insulation core material, and then the sealing edge of the thermal insulation piece is bonded on the external contour of the thermal insulation core material, so as to improve the proportion of the thermal insulation core material in the thermal insulation piece, which is beneficial to improve the thermal insulation effect.

[0008] In an embodiment, the film material comprises a substrate layer and an adhesive layer disposed on one side of the substrate layer for bonding part of the film material to part of the thermal insulation core material and for bonding part of the film material to part of another film material.

[0009] In an embodiment, the film material further comprises a second bonding portion formed between the second overlapping portion and the third overlapping portion, the second bonding portion is formed by the second overlapping portion and bonded to the third overlapping portion.

[0010] In an embodiment, the length of the second bonding portion in the direction away from the second overlapping portion is greater than 3mm.

[0011] In an embodiment, the length of the first bonding portion in the direction away from the third overlapping portion is greater than 3mm.

[0012] In an embodiment, the first overlapping portion comprises an overlapping region and a reinforcing region, the width of the reinforcing region is greater than the width of the overlapping region.

[0013] In an embodiment, the film material in the unfolded state defines a bottom surface attachment region, a side surface attachment region, a top surface attachment region, a first overlapping region, a second overlapping region, a third overlapping region, a first bonding region and a second bonding region; the side surface attachment region is disposed on both sides of the bottom surface attachment region along a first direction, the top surface attachment region is disposed on one side of the side surface attachment region away from the bottom surface attachment region; the third overlapping region is disposed on both sides of the bottom surface attachment region along a second direction; the first bonding region is disposed on one side of the third overlapping region away from the bottom surface attachment region; the first overlapping region is disposed on both sides of the side surface attachment region along the second direction; the second overlapping region is disposed on both sides of the top surface attachment region along the second direction; the second bonding region is located at the four corners of the film material in the unfolded state and adjacent to the second overlapping region.

[0014] In an embodiment, the film material is provided with a notch at each of the four corners of the film material, the film material defines a first edge and a second edge at the position of each notch; the first edge is parallel to the first direction and at least on one side of the second bonding region away from the second overlapping region; the second edge is parallel to the second direction and at least does not overlap with the bottom surface attachment region in the first direction.

[0015] In an embodiment, the film material is provided with notches at four corners thereof, and the film material defines a first edge and a second edge at each of the notches; the first edge is parallel to the first direction and is located at least at one side of the second bonding area away from the second overlapping area; the second edge is connected to the first edge at an end point thereof located at the third overlapping area, and the second edge extends in the first direction away from the first edge, and an angle between the second edge and the second direction is 22.5°-32.5°.

[0016] In an embodiment, the thermal insulation core material comprises one or more of a layer of fibrous material, a layer of fibrous-reinforced aerogel composite material, a layer of phase change material, and a layer of strain material.

[0017] In an embodiment, the layer of fibrous material is selected from one or more of a glass fiber mat, a pre-oxidized fiber mat, and a ceramic fiber mat.

[0018] In an embodiment, the layer of fibrous-reinforced aerogel composite material is selected from one or more of a glass fiber-reinforced aerogel mat, a pre-oxidized fiber-reinforced aerogel mat, and a ceramic fiber-reinforced aerogel mat.

[0019] The second aspect of the present application provides a packaging method for packaging a thermal insulation core material to form a thermal insulation member as described in the above embodiments, comprising:

[0020] folding the film material in an initial flat shape from the bottom surface of the thermal insulation core material to the top surface along two side surfaces respectively;

[0021] folding the part of the film material coplanar with the side surface to the end surface;

[0022] folding the part of the film material coplanar with the top surface to the end surface;

[0023] folding the part of the film material coplanar with the bottom surface to the end surface;

[0024] folding the part of the film material coplanar with the end surface to the top surface;

[0025] vacuumizing the film material and the thermal insulation core material and heat-pressing and bonding the film material.

[0026] In an embodiment, the film material further forms a second bonding portion between the second overlapping layer and the third overlapping layer, and after the step of folding the part of the film material coplanar with the top surface to the end surface, the method further comprises: bonding the second bonding portion with the corresponding part of the film material.

[0027] The third aspect of the present application provides a battery pack, comprising:

[0028] a plurality of battery cells; and

[0029] The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0030] The fourth aspect of the present application provides a vehicle, comprising:

[0031] A driving device; and

[0032] The above battery pack is used to supply power to the driving device. BRIEF DESCRIPTION OF DRAWINGS

[0033] Figure 1 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0034] Figure 2 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells. Figure 1 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0035] Figure 3 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0036] Figure 4 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells. Figure 1 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0037] Figure 5 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0038] Figure 6 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0039] Figure 7 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells. Figure 6 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0040] Figure 8 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0041] Figure 9 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0042] Figure 10 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells. Figure 9 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0043] Figure 11 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells. Figure 9 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0044] Figure 12 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0045] Figure 13 The above heat insulation member, one of the heat insulation members is arranged between two adjacent battery cells.

[0046] Explanation of main component symbols:

[0047] Thermal insulation 100

[0048] Thermal insulation core 10

[0049] Bottom surface 11

[0050] Top surface 13

[0051] Side surface 15

[0052] End surface 17

[0053] Film 30

[0054] First overlapping portion 31

[0055] Overlapping region 311

[0056] Strengthening region 313

[0057] Second overlapping portion 33

[0058] First bonding portion 35

[0059] First overlapping layer 331

[0060] Second overlapping layer 333

[0061] Second bonding portion 335

[0062] Third overlapping layer 337

[0063] Base material layer 37

[0064] Adhesive layer 39

[0065] Bottom surface attachment region 41

[0066] Side surface attachment region 42

[0067] Top surface attachment region 43

[0068] First overlapping region 44

[0069] Second overlapping region 45

[0070] First main body portion 451

[0071] First folding portion 453

[0072] Third overlapping region 46

[0073] Second main body portion 461

[0074] Second folding portion 463

[0075] First fitting area 47

[0076] Second fitting area 48

[0077] Gap 50

[0078] First side 51

[0079] Second side 53

[0080] Endpoint P

[0081] included angle α

[0082] Battery pack 200

[0083] Battery cell 210

[0084] Vehicle 300

[0085] Drive unit 310

[0086] First direction X

[0087] Second direction Y

[0088] Steps S1, S2, S3, S4, S5, S6 Detailed Implementation

[0089] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0090] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used in this application's specification is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.

[0091] To further illustrate the technical means and effects adopted by this application in achieving its intended purpose, the following detailed description of this application is provided in conjunction with the accompanying drawings and preferred embodiments.

[0092] Please refer to the following: Figure 1 and Figure 2 The heat insulation component 100 provided in this application embodiment includes a heat insulation core material 10 and a membrane material 30. The heat insulation core material 10 has an approximately cuboid structure and includes a bottom surface 11 and a top surface 13 disposed opposite to each other, two opposite side surfaces 15 and two opposite end surfaces 17 connecting the bottom surface 11 and the top surface 13. The membrane material 30 wraps around the outside of the heat insulation core material 10 to encapsulate the heat insulation core material 10.

[0093] In this embodiment, the thermal insulation core material 10 is a single-layer aerogel felt or a stack of multiple aerogel felts. The aerogel felt uses fiber felt such as glass fiber or ceramic fiber as the substrate. A prepared sol is bonded to the fiber felt through impregnation or spraying. The sol undergoes a sol-gel reaction in the substrate to form a gel felt. Then, the gel felt is chemically modified and finally prepared through a supercritical or atmospheric pressure drying process. Aerogel felt is a good thermal insulation material and can be used as a thermal insulation component in the batteries of new energy vehicles. However, aerogel material is fragile and therefore will shed powder, requiring encapsulation with a membrane material 30.

[0094] In other embodiments, the thermal insulation core material 10 may also be a combination of one or more of the following: a fiber material layer, a fiber-reinforced aerogel composite material layer, a phase change material layer, and a strain material layer. The multilayered structure can be directly stacked together or bonded with an adhesive. This application does not impose any limitations on this. The fiber material layer is selected from one or more of glass fiber mat, pre-oxidized fiber mat, and ceramic fiber mat. The fiber-reinforced aerogel composite material layer is selected from one or more of glass fiber reinforced aerogel mat, pre-oxidized fiber reinforced aerogel mat, and ceramic fiber reinforced aerogel mat. The thermal insulation core material 10 using the above materials also suffers from the problem of being fragile and shedding powder, therefore it also needs to be encapsulated by a membrane material 30.

[0095] In this embodiment, the heat insulation core material 10 is a cuboid with a length of 253.5 mm, a width of 103.5 mm, and a thickness of 4.0-4.5 mm. The length of the heat insulation core material 10 refers to the length of the side connecting the bottom surface 11 and the side surface 15; the width refers to the length of the side connecting the bottom surface 11 and the end surface 17; and the thickness refers to the length of the side connecting the end surface 17 and the side surface 15. In other embodiments, the dimensions of the heat insulation core material 10 can be set according to specific usage requirements, and the shape of the heat insulation core material 10 can also be set as other hexahedrons; this application does not impose any limitations on this.

[0096] The membrane material 30 includes a substrate layer 37 and an adhesive layer 39. The substrate layer 37 is made of polyethylene glycol terephthalate (PET), and the adhesive layer 39 is made of thermosetting adhesive. The adhesive layer 39 is disposed on one side of the substrate layer 37 and is used to bond a portion of the membrane material 30 to a portion of the heat insulation core material 10, and to bond a portion of the membrane material 30 to each other.

[0097] In this embodiment, the thickness of the membrane material 30 is 0.05±0.005mm, wherein the thickness of the substrate layer 37 is 0.025±0.002mm, and the thickness of the adhesive layer 39 is 0.025±0.002mm. In other embodiments, the thickness of the membrane material 30 can also be set according to specific application requirements, and this application does not impose any restrictions on it.

[0098] Specifically, the membrane material 30 is folded from the bottom surface 11 of the heat insulation core material 10 along both sides 15 to the top surface 13, and at least partially overlaps on the top surface 13 to form a first overlapping portion 31. The membrane material 30 also has second overlapping portions 33 formed on both end faces 17, each comprising a first overlapping layer 331, a second overlapping layer 333, and a third overlapping layer 337 stacked sequentially. The first overlapping layer 331 is folded from the side faces 15 onto the end faces 17 of the heat insulation core material 10. The second overlapping layer 333 is folded from the top surface 13 onto the end faces 17 of the heat insulation core material 10, and at least partially covers the first overlapping layer 331. The third overlapping layer 337 is folded from the bottom surface 11 onto the end faces 17 of the heat insulation core material 10, and at least partially covers the first overlapping layer 331 and the second overlapping layer 333. The membrane material 30 also has a first bonding portion 35, which extends from the third overlapping layer 337 to the top surface 13 and is bonded to a portion of the membrane material 30 located on the top surface 13.

[0099] In this process, a portion of the membrane material 30 is bonded to the surface of the heat insulation core material 10, thereby allowing the adhesive layer 39 to bond the substrate layer 37 and the heat insulation core material 10 together. Another portion of the membrane materials 30 overlap with each other, and the adhesive layer 39 is used to bond the overlapping portion of the substrate layer 37 together, thereby achieving the encapsulation structure.

[0100] The heat insulation component 100 provided in this application embodiment forms a first overlapping portion 31 on the top surface 13 of the heat insulation core material 10 by setting a membrane material 30, and forming a second overlapping portion 33 on the two end faces 17 of the heat insulation core material 10. The second overlapping portion 33 is bonded to the membrane material 30 located on the top surface 13 by a first adhesive portion connected to the third overlapping layer 337, so that the membrane material 30 can encapsulate the heat insulation core material 10 along the outer contour of the heat insulation core material 10, thereby making the sealing edge of the heat insulation component 100 fit on the outer contour of the heat insulation core material 10, thereby increasing the proportion of the heat insulation core material 10 in the heat insulation component 100, which is beneficial to improving the heat insulation effect.

[0101] In this embodiment, the width of the first overlapping portion 31 is greater than or equal to 5 mm. Specifically, the first overlapping portion 31 is the overlapping area of ​​the membrane material 30 that extends from the two side surfaces 15 to the top surface 13. The membrane materials 30 are attached to each other at the position of the first overlapping portion 31, thereby fixing the membrane material 30 and encapsulating the heat insulation core material 10.

[0102] Please seeFigure 3 In another embodiment, the first overlapping portion 31 includes an overlapping area 311 and a reinforcing area 313, the width of which is greater than the width of the overlapping area 311. Specifically, the overlap width of the portion of membrane material 30 corresponding to the reinforcing area 313 is greater than the overlap width of the portion of membrane material 30 corresponding to the overlapping area 311. The reinforcing area 313 is used to further strengthen the bonding strength of the membrane material 30, thereby strengthening the robustness of the thermal insulation component 100 structure. The width of the reinforcing area 313 can be one to two times that of the overlapping area 311. For example, when the width of the overlapping area 311 is 5 mm, the width of the reinforcing area 313 can be 10 mm, or when the width of the overlapping area 311 is 3 mm, the width of the reinforcing area 313 can be 5 mm. There can be one, two, or more reinforcing areas 313; this application does not limit this.

[0103] In this embodiment, the length of the first bonding portion 35 in the direction away from the third overlapping layer 337 is greater than 3 mm. Specifically, the first bonding portion 35 is connected to and bonded to the top surface 13 by the third overlapping portion to fix the relative positions of the first overlapping layer 331, the second overlapping layer 333, and the third overlapping layer 337, so that the first overlapping layer 331, the second overlapping layer 333, and the third overlapping layer 337 are sequentially stacked on the end face 17. By setting the length of the first bonding portion 35 from the third overlapping layer 337 to the top surface 13 to be greater than 3 mm, the first bonding portion 35 can be more stably bonded to the top surface 13, thereby ensuring that the stress generated by the superposition of the first overlapping layer 331, the second overlapping layer 333, and the third overlapping layer 337 is less likely to cause the first bonding portion 35 to fall off the top surface 13, which is beneficial to strengthening the robustness of the thermal insulation component 100 structure.

[0104] Please see Figure 4 In this embodiment, the membrane material 30 further includes a second bonding portion 335, which is formed between the second overlapping layer 333 and the third overlapping layer 337 and is bonded to the third overlapping layer 337. Specifically, the second bonding portion 335 extends from the second overlapping layer 333 and fixes the relative position between the second overlapping layer 333 and the third overlapping layer 337 by bonding with the third overlapping layer 337.

[0105] In this embodiment, the length of the second bonding portion 335 in the direction away from the second overlapping layer 333 is greater than 3 mm. Specifically, the second bonding portion 335 extends from the second overlapping layer 333 and abuts against the third overlapping area 46, thereby fixing the second overlapping layer 333 at the bonding end face 17. When the length of the second bonding portion 335 in the direction away from the second overlapping layer 333 is greater than 3 mm, it can be more firmly bonded to the third overlapping area 46, thereby preventing the stress generated by the folding of the second overlapping layer 333 from causing the second bonding portion 335 to fall off.

[0106] Please see Figure 5 In this embodiment, the membrane material 30 is approximately rectangular when fully unfolded. The unfolded membrane material 30 is defined with a bottom attachment area 41, a side attachment area 42, a top attachment area 43, a first overlapping area 44, a second overlapping area 45, a third overlapping area 46, a first bonding area 47, and a second bonding area 48. The side attachment areas 42 are located on both sides of the bottom attachment area 41 along the first direction X, and the top attachment area 43 is located on the side of one of the side attachment areas 42 away from the bottom attachment area 41. The third overlapping area 46 is located on both sides of the bottom attachment area 41 along the second direction Y. The first bonding area 47 is located on the side of the third overlapping area 46 away from the bottom attachment area 41. The first overlapping area 44 is located on both sides of the side attachment area 42 along the second direction Y. The second overlapping area 45 is located on both sides of the top attachment area 43 along the second direction Y. The second bonding area 48 is located at the four corners of the unfolded membrane material 30 and is adjacent to the second overlapping area 45.

[0107] The bottom surface attachment area 41 is provided on the bottom surface 11 of the heat insulation core material 10 and is used for attachment to the bottom surface 11. The side surface attachment area 42 is provided on the side surface 15 of the heat insulation core material 10 and is used for attachment to the side surface 15. The top surface attachment area 43 is provided on the top surface 13 of the heat insulation core material 10 and is used for attachment to the top surface 13.

[0108] Please refer to the following: Figure 4 and Figure 5 The first overlapping area 44 is used to form the first overlapping layer 331, the second overlapping area 45 is used to form the second overlapping layer 333, the second bonding area 48 is used to form the second bonding portion 335, the third overlapping area 46 is used to form the third overlapping layer 337, and the first bonding area 47 is used to form the first bonding portion 35.

[0109] Please refer to the following: Figure 6 and Figure 7 In another embodiment, the membrane material 30 in its unfolded state has notches 50 at its four corners. A first side 51 and a second side 53 are formed at the locations of the notches 50 on the membrane material 30. The first side 51 is parallel to the first direction X and is located on the second bonding area 48. That is, compared to... Figure 5The membrane material 30 shown in this embodiment has the second bonding area 48 located at the corners cut off, thereby reducing the area of ​​the second bonding area 48. In this embodiment, the length of the second bonding portion 335 in the direction away from the second overlapping layer 333 is not limited. The second bonding portion 335 is only used to overlap with the third overlapping layer 337 to ensure that the membrane material 30 has a sealed structure at the end face 17. By reducing the area of ​​the second bonding area 48, the area of ​​the second bonding portion 335 after encapsulation can be reduced, thereby reducing the thickness of the second overlapping portion 33. This helps to avoid the formation of high-hardness sharp corners due to the overlapping of multiple membrane materials 30, which could cause damage to the sharp corners due to collisions during the transportation of the heat insulation component 100.

[0110] The second side 53 is connected to the first side 51, and the second side 53 is parallel to the second direction Y and does not overlap with the attachment area of ​​the bottom surface 11 at least in the first direction X. Specifically, the second side 53 can be opened at any position from the second bonding area 48 to the first overlapping area 44, so that the thickness of the membrane material 30 after the notch 50 is opened is reduced after folding to form the second overlapping part 33. This helps to avoid the formation of high-hardness sharp corners due to the overlapping of multiple layers of membrane material 30, which could lead to damage to the sharp corners due to collisions during the transportation of the heat insulation component 100.

[0111] Please see Figure 8 In another embodiment, the membrane material 30 in its unfolded state has notches 50 at its four corners. At the locations of the notches 50, the membrane material 30 forms a first side 51 and a second side 53. The first side 51 is parallel to the first direction X and is located on the second bonding area 48. The endpoint P connecting the second side 53 to the first side 51 is located in the third overlap area 46 and extends in the first direction X away from the first side 51. The angle α between the second side 53 and the second direction Y is 22.5°-32.5°. Specifically, in Figure 9 Based on the embodiment shown, the area of ​​the notch 50 can be further increased by setting the second side 53 to have an angle α with the second direction Y. By setting the endpoint P connecting the first side 51 and the second side 53 to be located in the third overlapping area 46, the length of the third overlapping area 46 after the notch 50 is opened in the first direction X can be less than the width of the heat insulation core material 10. This prevents the third overlapping layer 337 from covering the sharp corner of the end face 17, thereby reducing the thickness of the sharp corner and helping to avoid the formation of a high-hardness sharp corner by the overlapping of multiple layers of membrane material 30.

[0112] The angle α between the second side 53 and the second direction Y can be set according to specific usage requirements. In this embodiment, when the second side 53 is opened, the size of the angle α changes the position of the intersection point of the second side 53 and the side of the first bonding area 47 away from the bottom surface 11 attachment area, while the position of the endpoint P connecting the second side 53 and the first side 51 in the first direction X remains unchanged. If the angle α is too large, the distance between the third overlapping layer 337 formed after encapsulation and the edge of the end face 17 will be large, which may affect the sealing effect. If the angle α is too small, the distance between the third overlapping layer 337 formed after encapsulation and the edge of the end face 17 will be small, causing the third overlapping layer 337 formed after encapsulation to be close to the sharp corner of the end face 17, resulting in a poor effect in reducing the hardness of the sharp corner.

[0113] The heat insulation component 100 provided in this application embodiment can reduce the thickness of the second overlapping portion 33 formed by the film material 30 folded and packaged onto the heat insulation core material 10 by removing the corners of the film material 30 in the unfolded state. While ensuring the heat insulation core material 10 is sealed and packaged, the thickness of the sharp corners formed by the film material 30 covering the end face 17 of the heat insulation core material 10 can also be reduced, thereby avoiding the formation of high-hardness sharp corners by the overlapping of multiple layers of film material 30. This helps to prevent air leakage caused by damage to the film material 30 at the sharp corners during the use or transportation of the heat insulation component 100.

[0114] Please see Figure 9 This application embodiment also provides a method for encapsulating a heat insulation component 100, which includes:

[0115] Step S1: Fold the membrane material 30 from the bottom surface 11 of the heat insulation core material 10 along the two side surfaces 15 to the top surface 13;

[0116] Step S2: Fold the portion of the membrane material 30 that is coplanar with the side surface 15 to the end face 17;

[0117] Step S3: Fold the portion of the membrane material 30 that is coplanar with the top surface 13 to the end surface 17;

[0118] Step S4: Fold the portion of the membrane material 30 that is coplanar with the bottom surface 11 to the end surface 17;

[0119] Step S5: Fold the portion of the membrane material 30 that is coplanar with the end face 17 to the top face 13;

[0120] Step S6: Vacuum the membrane material 30 and the heat insulation core material 10 and hot-press the membrane material 30 together.

[0121] The structure of the heat insulation component 100 provided in the embodiments of this application will be further described below in conjunction with the above-described encapsulation method.

[0122] Please see Figure 10In step S1, the membrane material 30 is folded from the bottom surface 11 along the contours of the side surface 15 and top surface 13 of the heat insulation core material 10 to form a cylindrical structure, thereby enclosing the heat insulation core material 10 inside. The two top surface attachment areas 43 partially overlap to form a first overlap 31.

[0123] After step S1, the method further includes hot-pressing the first overlapping portion 31 to fix it so that the overlapping portions of the membrane material 30 are bonded together, thereby fixing the structure formed by the membrane material 30 after step S1.

[0124] Please refer to the following: Figure 5 and Figure 11 In step S2, the first overlapping area 44, which is coplanar with the side surface 15, is folded along the contour of the heat insulation core material 10 toward the end face 17, thereby forming the first overlapping layer 331.

[0125] The second overlapping region 45 includes a first main body portion 451 and a first folded portion 453. The first folded portion 453 is located between the first overlapping region 44 and the first main body portion 451. When the first overlapping region 44 is folded toward the end face 17, the first folded portion 453 is driven by the first overlapping region 44 to fold with the first main body portion 451 to form a folded angle structure. The third overlapping region 46 includes a second main body portion 461 and a second folded portion 463. The second folded portion 463 is located between the second main body portion 461 and the first overlapping region 44. When the first overlapping region 44 is folded toward the end face 17, the second folded portion 463 is driven by the first overlapping region 44 to fold with the second main body portion 461 to form a folded angle structure.

[0126] Following step S2, the process further includes heat-pressing the overlapping areas of the first folded portion 453 and the first main body portion 451 to bond the first folded portion 453 to the first main body portion 451. Similarly, heat-pressing the overlapping areas of the second folded portion 463 and the second main body portion 461 to bond the second folded portion 463 to the second main body portion 461. This process then fixes the structure formed by the membrane material 30 after step S2.

[0127] Please refer to the following: Figure 4 and Figure 8 In step S3, the second overlapping area 45, which is coplanar with the top surface 13, is folded along the contour of the heat insulation core material 10 toward the end surface 17, thereby forming a second overlapping layer 333. The length of the second overlapping area 45 in the second direction Y is the same as the thickness of the heat insulation core material 10, such that the second overlapping layer 333 extends exactly from the side of the end surface 17 near the top surface 13 to the side of the end surface 17 near the bottom surface 11.

[0128] The second bonding area 48 overlaps with the third overlapping area 46 as the second overlapping area 45 is folded. After step S3, the second bonding area 48 is bonded to the third overlapping area 46, which is coplanar with the bottom surface 11, to form the second bonding portion 335.

[0129] Steps S4 and S5 specifically involve first folding the third overlapping area 46 along the contour of the end face 17 of the heat insulation core material 10, so that the third overlapping area 46 covers the end face 17 to form a third overlapping portion, and then folding the first bonding area 47 connected to the third overlapping area 46 along the contour of the top surface 13 of the heat insulation core material 10 to form a first bonding portion 35 for bonding with a portion of the membrane material 30 on the top surface 13.

[0130] In step S6, by first evacuating the membrane material 30 and the heat insulation core material 10, and then hot-pressing the membrane material 30 together, the membrane material 30 and the heat insulation core material 10 in the encapsulated heat insulation component 100 are tightly bonded together. This prevents the heat insulation component 100 from leaking and breaking due to residual gas inside when subjected to external pressure.

[0131] The encapsulation method provided in this application embodiment involves sequentially folding and attaching the membrane material 30 along the outer contour of the heat insulation core material 10, so that the sealing edge of the final heat insulation component 100 is attached to the outer contour of the heat insulation core material 10. This increases the proportion of the heat insulation core material 10 in the heat insulation component 100, which is beneficial to improving the heat insulation effect. The heat insulation component 100 provided in this application embodiment, by providing notches 50 at the four corners of the membrane material 30, can further reduce the thickness of the second overlapping portion 33, thereby preventing the membrane material 30 on the end face 17 from becoming too hard due to excessive layers, thus avoiding damage and air leakage caused by excessive hardness, which is beneficial to improving the structural robustness of the heat insulation component 100.

[0132] Please see Figure 12 This application embodiment also provides a battery pack 200, which includes a plurality of battery cells 210 and at least one heat insulation member 100 as described in the above embodiments. A heat insulation member 100 is disposed between two adjacent battery cells 210 for heat insulation of the battery cells 210.

[0133] The battery pack 200 provided in this application embodiment improves the heat insulation effect by incorporating the heat insulation component 100 as described in the above embodiment. Since the membrane 30 of the heat insulation component 100 is encapsulated along the contour of the heat insulation core material 10, the contact surfaces between the battery cell 210 and the heat insulation component 100 essentially correspond to the top surface 13 and bottom surface 11 of the heat insulation core material 10 (the thickness of the membrane 30 is negligible). Because the heat insulation component 100 is a closed structure formed by hot pressing after vacuuming, it has high strength. When the battery pack 200 is assembled, the heat insulation component 100 will not leak or break due to excessive pressure, which helps improve the quality of the battery pack 200.

[0134] Please see Figure 13 This application also provides a vehicle 300, which includes a drive unit 310 and a battery pack 200 as described in the above embodiments, the battery pack 200 being used to supply power to the drive unit 310.

[0135] Those skilled in the art should recognize that the above embodiments are only used to illustrate this application and are not intended to limit this application. Any appropriate changes and variations made to the above embodiments within the essential spirit and scope of this application fall within the scope of protection claimed in this application.

Claims

1. A heat insulation component, characterized in that, include: Thermal insulation core material, the thermal insulation core material including a bottom surface and a top surface disposed opposite each other, two opposite side surfaces and two opposite end surfaces connected between the bottom surface and the top surface; and A membrane material is wrapped around the outside of the heat insulation core material to encapsulate the heat insulation core material. The membrane material is folded from the bottom surface along the two sides to the top surface and at least partially overlaps on the top surface to form a first overlapping portion. The membrane material also has a second overlapping portion formed on each of the two end faces. The second overlapping portion includes a first overlapping layer, a second overlapping layer, and a third overlapping layer stacked sequentially. The first overlapping layer is folded from the side face onto the heat insulation core material. The second overlapping layer is folded from the top face onto the end face and at least partially covers the first overlapping layer. The third overlapping layer is folded from the bottom face onto the end face and at least partially covers the second overlapping layer. The membrane material also has a first bonding portion, which extends from the third overlapping layer onto the top face and bonds with the membrane material located on the top face.

2. The heat insulation component as described in claim 1, characterized in that, The membrane material includes a substrate layer and an adhesive layer. The adhesive layer is disposed on one side of the substrate layer and is used to bond a portion of the membrane material to a portion of the heat insulation core material, and to bond a portion of the membrane material to each other.

3. The heat insulation component as described in claim 1, characterized in that, The membrane material further includes a second bonding portion formed between the second overlapping layer and the third overlapping layer, the second bonding portion being formed by extending from the second overlapping layer and bonding with the third overlapping layer.

4. The heat insulation component as described in claim 3, characterized in that, The length of the second bonding portion in the direction away from the second overlapping layer is greater than 3 mm.

5. The heat insulation component as described in claim 1, characterized in that, The length of the first bonding portion in the direction away from the third overlapping layer is greater than 3 mm.

6. The heat insulation component as claimed in claim 1, characterized in that, The first overlapping portion includes an overlapping area and a reinforcing area, wherein the width of the reinforcing area is greater than the width of the overlapping area.

7. The heat insulation component as claimed in claim 1, characterized in that, The membrane material in its unfolded state is defined with a bottom attachment area, a side attachment area, a top attachment area, a first overlapping area, a second overlapping area, a third overlapping area, a first bonding area, and a second bonding area. The side attachment areas are located on both sides of the bottom attachment area along a first direction, and the top attachment area is located on one side of the side attachment area away from the bottom attachment area. The third overlapping area is located on both sides of the bottom attachment area along a second direction. The first bonding area is located on the side of the third overlapping area away from the bottom attachment area. The first overlapping area is located on both sides of the side attachment area along the second direction. The second overlapping area is located on both sides of the top attachment area along the second direction. The second bonding area is located at the four corners of the membrane material in its unfolded state and is adjacent to the second overlapping area.

8. The heat insulation component as claimed in claim 7, characterized in that, The membrane material has notches at its four corners, and a first side and a second side are formed at each notch. The first side is parallel to the first direction and is located at least on the side of the second bonding area away from the second overlapping area. The second side is parallel to the second direction and does not overlap with the bottom attachment area at least in the first direction.

9. The heat insulation component as claimed in claim 7, characterized in that, The membrane material has notches at its four corners, and a first side and a second side are formed at each notch. The first side is parallel to the first direction and is located at least on the side of the second bonding area away from the second overlapping area. The endpoint of the second side connecting to the first side is located in the third overlapping area, and the second side extends in the first direction away from the first side. The angle between the second side and the second direction is 22.5°-32.5°.

10. The heat insulation component as claimed in claim 1, characterized in that, The thermal insulation core material includes any one or more of the following: fiber material layer, fiber-reinforced aerogel composite material layer, phase change material layer, and strain material layer.

11. A packaging method for encapsulating a thermal insulation core material to form a thermal insulation component as described in any one of claims 1-10, characterized in that, include: The membrane material, initially in a flat shape, is folded from the bottom surface of the heat insulation core material along both sides to the top surface; Fold the portion of the membrane material that is coplanar with the side surface to the end face; Fold the portion of the membrane material that is coplanar with the top surface to the end face; Fold the portion of the membrane material that is coplanar with the bottom surface to the end face; Fold the portion of the membrane material that is coplanar with the end face onto the top surface; The membrane material and the heat insulation core material are evacuated and then the membrane material is hot-pressed and bonded together.

12. The packaging method as described in claim 11, characterized in that, The membrane material further includes a second bonding portion formed between the second overlapping layer and the third overlapping layer. After the step of folding the portion of the membrane material that is coplanar with the top surface to the end surface, the method further includes: bonding the second bonding portion to the corresponding portion of the membrane material.

13. A battery pack, characterized in that, include: Multiple battery cells; as well as At least one heat insulation element as described in any one of claims 1-10, wherein one of the heat insulation elements is disposed between two adjacent cells.

14. A vehicle, characterized in that, include: Drive unit; as well as The battery pack of claim 13 is used to supply power to the drive device.

Images