Insulating element, method for producing insulating element, and housing component comprising insulating element

Abstract

The invention relates to an insulating element (100), in particular for insulating a housing component of an energy store or an energy converter, for example for an electrically driven motor vehicle, the insulating element (100) comprising or being formed from an insulating material (102), wherein the insulating material (102) comprises or is formed from at least one additive (104a, 104b), in particular for increasing the heat resistance and / or electrical resistance and / or mechanical resistance of the insulating element (100). The invention also relates to a method for producing the insulating element (100).

Description

Technical Field

[0001] The present invention relates to an insulating element, a method for manufacturing an insulating element, and a housing component including the insulating element. Background Technology

[0002] There is a risk of so-called thermal penetration (also known as thermal runaway) in the casing components of energy storage devices or energy converters, especially batteries, accumulators, or fuel cells. Thermal penetration generally refers to an exothermic chemical reaction or overheating of the technical equipment due to a self-reinforcing heat-generating process. Runaway often leads to fire or explosion, thus damaging the equipment due to overpressure (bursting). For simplicity, the terms energy storage device and energy converter are used interchangeably below; that is, the design options and advantages listed with reference to energy storage devices also apply similarly to energy converters, and vice versa.

[0003] Therefore, it is necessary to protect the casing of this type of energy storage from thermal runaway, thereby preventing it from spreading to other components inside and / or outside the energy storage.

[0004] However, known solutions are heavy, bulky, and sometimes have complex multi-level structures. Furthermore, this type of solution typically does not provide comprehensive protection. Summary of the Invention

[0005] Therefore, the object of the present invention is to provide an isolation element that provides reliable and simple protection, particularly against thermal runaway and / or electrical runaway. Another object of the present invention is to provide a method for manufacturing such an isolation element.

[0006] Regarding the insulating element, this objective is achieved according to the invention by an insulating element having the features of claim 1. Regarding the method, this objective is achieved according to the invention by a method having the features of claim 9. Advantageous designs, improvements, and variations are given in the dependent claims. The advantages and preferred designs listed regarding the housing member are meaningfully applied to the method, and vice versa.

[0007] Specifically, the purpose of the insulating element is achieved by insulating elements, particularly insulating elements for the housing components of energy storage devices, such as those used in electrically driven motorized vehicles, wherein the insulating element comprises or is formed of insulating material. The insulating material is particularly used to prevent thermal and / or electrical penetration of the housing components.

[0008] However, the application is not limited to the housing components of the energy storage device, and other components that require the type of isolation mentioned above can also be considered.

[0009] In this case, the insulating material includes or is formed from at least one additive. The additive is particularly used to improve the heat resistance and / or electrical and / or mechanical resistance of the insulating material.

[0010] This achieves reliable protection for the shell components without resorting to the large and complex isolation elements already mentioned, which in turn simplifies the overall construction of the shell components to be protected.

[0011] According to one embodiment, the insulating element comprises insulating paper. Alternatively, the insulating element is constructed as insulating paper. In this case, preferably, the insulating material is applied to the surface of the insulating paper or incorporated into the interior of the insulating paper along with at least one additive. By designing the insulating element as insulating paper, a versatile and easy-to-use insulating element is obtained, which can be easily processed and adaptable in many ways to different types of housing components.

[0012] To achieve a barrier element that is as thin as possible compared to known solutions, the barrier element has a thickness ranging from 0.2 mm to 2 mm, preferably from 0.5 mm to 1.5 mm, and especially 1 mm. Therefore, the barrier element is thin enough to provide a simple and space-saving design, yet thick enough to meet protection requirements.

[0013] Advantageously, the insulating element may comprise, or be formed entirely or partially of, insulating material. In this case, for example, the hazardous area of ​​the housing member may be specifically protected by the portion of the insulating element comprising insulating material, while other areas of the housing member may be protected solely by the insulating element. When the insulating element is fully applied or installed, the housing member is preferably surrounded by at least all external areas and sides by the insulating element. In this context, alternatively, the housing member may be specified to comprise multiple components, such as two components, all of which are wholly or partially provided with insulating elements and, for example, joined together.

[0014] According to a preferred design, at least one additive comprises or is formed of an expanded material.

[0015] Within the scope of this application, the term "expandable material" can be understood as a material whose volume increases and corresponding density decreases under thermal action. For example, an expandable material can form a foamed ash layer that prevents the supply of oxygen and, consequently, the spread of flame. Specifically, the expandable material, in its activated state, i.e., upon the input of heat (e.g., during thermal penetration), forms a swollen layer. This layer comprises a very low density but is resistant to the effects of heat. Thus, in the event of thermal runaway, the expandable material forms a heat-resistant protective layer, which in particular protects against the impact of abrasive particles generated at high temperatures, such as those produced during this type of thermal penetration.

[0016] In particular, the expanding material is one of the following materials:

[0017] - Water-based expandable materials,

[0018] - Solvent-based expandable materials, or

[0019] - Epoxy-based expanding materials.

[0020] Water-based expansive materials have the advantages of being environmentally friendly and low-cost.

[0021] In contrast, solvent-based expandable materials offer the advantage of a smooth surface texture and thus create a particularly flat and clean surface. A flat and clean surface is important because dusty, porous, or rough surfaces increase the chance of heat penetration and are therefore undesirable.

[0022] Epoxy-based expanded materials offer the advantage of being extremely durable and therefore usable in “harsh” environments without diminishing or losing their protective effect.

[0023] In particular, the thermal properties of expandable materials are specifically determined by their chemical composition. Particularly suitable expandable materials include, for example, water-soluble alkali metal silicate binders. This type of material includes, for example, a silica content of up to 96% and an N-octyl-2-pyrrolidone content between 0.1% and 1%.

[0024] Alternatively or additionally, at least one additive includes an insulating material, particularly an aerogel, or is formed from an insulating material, particularly an aerogel. This type of insulating material has low thermal conductivity, thereby improving the heat resistance of the insulating element and thus the heat resistance of the housing component. These materials are usually also certified so that they can provide assurance regarding heat resistance and therefore correspond to and meet the standards required by official requirements. Such certification or testing is, for example, the UL94 flame test. Therefore, by constructing the additive as an insulating material, the thermal protection of the insulating element can be improved. In addition to the thermal protection of aerogels, they can also prevent electrical breakdown, thus further improving electrical withstand capability when using aerogels. Another advantage is that good thermal conductors generally also have good electrical conductivity. Therefore, in addition to their primary purpose as thermal insulators, they can also be used as electrical insulators.

[0025] Suitable aerogels include, for example, synthetic amorphous silicate solids constructed to be hydrophilic. This type of aerogel has a particle size, for example, in the range of 1 to 70 µm, preferably in the range of 1 to 20 µm, and particularly in the range of 10 to 15 µm. Furthermore, these aerogels have a pore size in the range of 1 to 50 nm, preferably in the range of 10 to 30 nm, and particularly in the range of 15 to 25 nm. The thermal conductivity of this type of aerogel has a value in the range of 0.025 to 0.03 W / (mK).

[0026] According to another alternative or supplementary embodiment, at least one additive has a nonwoven fabric and / or fiber or is formed from a nonwoven fabric and / or fiber. This type of fiber enhances the mechanical structure of the insulating element and thereby enhances its protective effect against mechanical stress. Examples of such fibers may be AES wool, insulating nonwoven fabric, glass fiber and / or metal fiber and / or metal alloy fiber and / or ceramic fiber.

[0027] To improve the electrical and mechanical withstand properties of the insulating element, at least one additive may have ceramic particles or be formed from ceramic particles. This improves protection, for example, against AC / DC breakdown voltage.

[0028] Specifically, the objective of this method is achieved through a method for manufacturing insulating elements. The method includes the following steps:

[0029] - Provide isolation elements;

[0030] - Adding and / or applying insulating material to the interior or surface of the insulating element;

[0031] - Dry insulation element.

[0032] Preferably, an insulating element is provided in the space provided for coating.

[0033] When adding or applying insulating material to the surface or interior of an insulating element, known application methods are preferably employed. Such methods include, but are not limited to, spraying, electroplating, powder coating, or thermal spraying. By applying known methods, low-cost manufacturing of the insulating element can be achieved.

[0034] According to one embodiment of the method, the insulating material is added wholly or partially to the insulating element and / or the insulating material is applied wholly or partially to the surface of the insulating element. This achieves personalized protective capabilities of the insulating material, allowing the insulating element to be adapted for use in a housing component.

[0035] In an advantageous manner, at least one additive is mixed into the insulating material, or the insulating material is at least one additive. This design takes into account improving the protective effect of the insulating element.

[0036] Furthermore, within the scope of this application, a housing component is disclosed and claimed, particularly for a housing component of an energy storage device, for example, for an electrically driven motorized vehicle, wherein an insulating element is mounted, particularly adhered, to the inner and / or outer side of the housing component. The insulating element is, in particular, the insulating element already described.

[0037] The housing component may in particular relate to energy storage devices and, for example, to energy storage devices for electrically driven motorized vehicles. If a protective element forms at least a portion of the housing component, the housing component is preferably, but not limited to, constructed as a multi-piece structure, such that at least a portion of the housing component is formed by the protective element. However, it is also conceivable that the entire housing component is formed by, and in particular, constituted by, protective elements.

[0038] Preferably, the insulating element is wholly or partially installed, especially adhered to, the inside and / or outside of the housing member. Attached Figure Description

[0039] Other preferred features and / or advantages of the invention are illustrated in the accompanying drawings and described below.

[0040] In the attached diagram:

[0041] Figure 1 A schematic diagram of an insulating element according to a first embodiment of the invention is shown, the insulating element comprising insulating material entirely embedded within the insulating element;

[0042] Figure 2 A schematic diagram of a barrier element according to a second embodiment of the invention is shown, the barrier element comprising a barrier material partially embedded therein;

[0043] Figure 3 A schematic diagram of an insulating element according to a third embodiment of the invention is shown, the insulating element comprising insulating material applied entirely to the upper side of the insulating element;

[0044] Figure 4 A schematic diagram of an insulating element according to a fourth embodiment of the invention is shown, the insulating element comprising insulating material partially applied to the upper side of the insulating element;

[0045] Figure 5 A schematic diagram of an insulating element according to a fifth embodiment of the invention is shown, the insulating element comprising alternative insulating materials fully embedded within the insulating element;

[0046] Figure 6A schematic diagram of an insulating element according to a sixth embodiment of the invention is shown, the insulating element comprising an alternative insulating material partially embedded therein;

[0047] Figure 7 A schematic diagram of an insulating element according to a seventh embodiment of the invention is shown, the insulating element comprising insulating material applied entirely to the upper side of the insulating element;

[0048] Figure 8 A schematic diagram of an insulating element according to an eighth embodiment of the invention is shown, the insulating element comprising insulating material partially applied to the upper side of the insulating element;

[0049] Figure 9 A schematic diagram of a housing component including insulating elements on the inner and outer sides is shown;

[0050] Figure 10 A schematic diagram of a block diagram for manufacturing a barrier element including a barrier material is shown.

[0051] In all the accompanying drawings, the same or functionally equivalent elements are given the same reference numerals. Detailed Implementation

[0052] refer to Figure 1 A schematic diagram of the isolation element 100 according to a first embodiment is shown. The isolation element 100 is preferably configured for a housing component, and particularly for a housing component of an energy storage device, for example, for an electrically driven motor vehicle.

[0053] The insulating element 100 is preferably constructed as insulating paper. It also includes or is formed of insulating material 102. The insulating material 102 is used in particular to improve the heat resistance and / or electrical resistance and / or mechanical resistance of the insulating material 102, and thus also improves the heat resistance and / or electrical resistance and / or mechanical resistance of the insulating element 100.

[0054] According to Figure 1 In this embodiment, the insulating material 102 is entirely embedded in the insulating element 100. In other words, the insulating element 100 preferably has the same amount of insulating material 102 at each location. Alternatively, the amount of insulating material 102 may vary partially within the insulating element 100.

[0055] To further enhance the aforementioned tolerance, the insulating element 100 also includes an additive 104a, which, according to... Figure 1 In one embodiment, thermal insulation material is used. This is in... Figure 1 The text uses dotted patterns to represent the symbols graphically.

[0056] For example, aerogel has proven advantageous as a suitable insulation material. This type of material can improve heat resistance for several hours.

[0057] In addition, the insulating element 100 may include an adhesive layer (not shown) on one or more outer sides, which is used to attach the insulating element, in particular, to the housing member.

[0058] Preferably, the insulating material 100 has a thickness in the range of 0.2 mm to 2 mm, preferably in the range of 0.5 mm to 1.5 mm, and especially 1 mm. Therefore, the insulating element 100 is not shown to scale in the figures, but is shown significantly enlarged to illustrate its features more clearly.

[0059] exist Figure 2 In the schematic illustration of the insulating element 100 according to a second embodiment of the invention, the insulating material 102 is only partially (i.e., when viewed in the image plane) embedded in the left half of the insulating element 100. The right half in this case comprises, for example, only the substrate of the insulating element 100.

[0060] In a similar manner, according to Figure 2 The insulating element 100 also additionally includes an additive 104a only in the left-side region, which is embedded in the insulating element 100 together with the insulating material 102.

[0061] This design allows for special protection against thermal stress, for example, the left side region of the insulating element 100.

[0062] In other respects, the insulating element 100 Figure 2 The illustrated implementation is similar in structure and function to Figure 1 The embodiments shown are consistent, and therefore reference can be made to the above description for this purpose.

[0063] The insulating element 100 according to the present invention Figure 3 The third embodiment, schematically illustrated, also includes an insulating material 102. However, unlike the two embodiments described above, this insulating material is disposed on the upper side 106 of the insulating element 100. In particular, the insulating material 102 is applied, for example, sprayed onto the upper side 106 of the insulating element 100. In other words, the insulating material 102 is located only on or on the surface of the insulating element 100 in the form of a layer.

[0064] Additionally, the insulating material 102 is applied entirely to the upper side 106 of the insulating element 100, thus completely covering the surface of the insulating element 100. It goes without saying that the insulating material 102 can be alternatively or additionally arranged in a similar manner, especially applied to the lower side 108 of the insulating element 100.

[0065] In addition, the insulating material 102 also includes an additive 104a, which is applied to the upper side 106 in a similar manner.

[0066] In other respects, the insulating element 100 Figure 3 The illustrated implementation is similar in structure and function to Figure 1 and Figure 2 The embodiments shown are consistent, and therefore reference can be made to the above description for this purpose.

[0067] Figure 4 The alternative to show Figure 3 A schematic diagram of the fourth embodiment of the third embodiment shown.

[0068] In this case, the insulating material 102 is only partially disposed on the upper side 106 of the insulating element 100. Specifically, and viewed in the image plane, the insulating material 102 is disposed only in the left-hand region of the upper side 106 of the insulating element 100, and therefore only in that region is enhanced protection provided.

[0069] In other respects, the insulating element 100 Figure 4 The illustrated implementation is similar in structure and function to Figures 1 to 3 The embodiments shown are consistent, and therefore reference can be made to the above description for this purpose.

[0070] Figure 5 A fifth embodiment of the insulating element 100 according to the present invention is illustrated schematically.

[0071] In the fifth embodiment of the insulating element 100, similar to the first embodiment, the insulating material 102 is completely embedded in the insulating element 100.

[0072] In other words, the insulating element 100 preferably includes the same amount of insulating material 102 at each location.

[0073] However, according to Figure 5 The embodiment has an alternative additive 104b, which is graphically shown through a strip pattern of the insulating element 100.

[0074] according to Figure 5 The additive 104b is fiber, particularly glass fiber and / or metal fiber and / or metal alloy fiber and / or ceramic fiber. For example, silicate fiber is also considered, and has proven to be particularly suitable. Using fiber as additive 104b particularly improves the mechanical resistance of the insulating material 102, and thereby improves the mechanical resistance of the insulating element 100. If the fiber is ceramic fiber, the electrical resistance is additionally improved due to its electrical insulating properties.

[0075] In other respects, the insulating element 100 Figure 5 The illustrated implementation is similar in structure and function to Figures 1 to 4 The embodiments shown are consistent, and therefore reference can be made to the above description for this purpose.

[0076] exist Figure 6 In the schematically illustrated insulating element 100 according to a sixth embodiment of the present invention, the insulating material 102 is only partially (i.e., viewed in the image plane) embedded in the left half of the insulating element 100. In this case, the right half is, for example, a substrate containing only the insulating element 100.

[0077] according to Figure 6 The isolation element 100 is also additionally included, in a similar manner, only in the left-hand region, by reference. Figure 5 The fiber-formed additive 104b is described, which is embedded in the insulating element 100 together with the insulating material 102.

[0078] Through this design, the left side region of the insulating element 100 can, for example, provide special protection against mechanical stress.

[0079] In other respects, the insulating element 100 Figure 6 The illustrated implementation is similar in structure and function to Figures 1 to 5 The embodiments shown are consistent, and therefore reference can be made to the above description for this purpose.

[0080] Figure 7 The schematic diagram illustrates a seventh embodiment of the isolation element 100 according to the present invention.

[0081] The insulating element 100 also includes the insulating material 102. However, as per [the provided text]... Figure 3 As in the embodiments described, the insulating material is disposed on the upper side 106 of the insulating element 100. In particular, the insulating material 102 is applied, for example, sprayed onto the upper side 106 of the insulating element 100. In other words, the insulating material 102 is located only on or on the surface of the insulating element 100 in the form of a layer.

[0082] Additionally, the insulating material 102 is applied entirely to the upper side 106 of the insulating element 100, thus completely covering the surface of the insulating element 100. It goes without saying that the insulating material 102 can also be arranged or supplementarily in a similar manner, especially applied to the lower side 108 of the insulating element 100.

[0083] In addition, the insulating material 102 also includes an additive 104b formed of fibers, which is applied to the upper side 106 in a similar manner.

[0084] In other respects, the insulating element 100 Figure 7The illustrated implementation is similar in structure and function to Figures 1 to 6 The embodiments shown are consistent, and therefore reference can be made to the above description for this purpose.

[0085] Figure 8 The alternative to show Figure 7 A schematic diagram of the eighth embodiment of the seventh embodiment shown.

[0086] In this case, the insulating material 102 is only partially disposed on the upper side 106 of the insulating element 100. Specifically, and viewed in the image plane, the insulating material 102 is disposed only in the left-hand region of the upper side 106 of the insulating element 100, and therefore preferably provides enhanced protection only in that area.

[0087] In other respects, the insulating element 100 Figure 8 The illustrated implementation is similar in structure and function to Figures 1 to 7 The embodiments shown are consistent, and therefore reference can be made to the above description for this purpose.

[0088] exist Figure 9 The image shows a housing component 110, which is particularly used for energy storage devices, for example, for electrically driven motorized vehicles.

[0089] Alternatively, housing component 110 may be an electrochemical cell, a battery cover or casing, a cell separator, a cell-to-cell separator, or generally a module of an energy storage device. In other words, any component constructed in the form of a housing and that is or may be part of an energy storage device can be considered housing component 110.

[0090] according to Figure 9 The housing member 110 has an isolation element 100 at its outer side 112 and its inner side 114. The isolation element 100 is in particular the isolation element 100 described above, and thus reference can be made to the above description for this purpose.

[0091] However, alternatively, the housing member 110 may have an insulating element 100 only at its outer side 112 or its inner side 114.

[0092] Therefore, the housing component 110 is adequately protected against thermal stress and / or electrical stress and / or mechanical stress in a simple and reliable manner.

[0093] Figure 10 The process flow for manufacturing the insulating element 100 is shown in block diagram form.

[0094] In the first step 116 of the method, an insulating element 100 is provided. The insulating element 100 is preferably not coated at this stage. In other words, the insulating element 100 does not yet include the insulating material 102 at this stage.

[0095] Preferably, this provision is implemented in an area set up for this purpose, such as a coating chamber.

[0096] In the second step 118 of the method, insulating material 102 is added to and / or applied to the interior or surface of insulating element 100. When insulating material 102 is added to insulating element 100, insulating material 102 is preferably incorporated into the material of insulating element 100. When insulating material 102 is applied to the surface of insulating element 100, insulating material 102 is preferably applied wholly or partially to the surface of insulating element 100 in the form of a protective layer.

[0097] In the third step 120 of the method, the insulating element 100, on which the insulating material 102 is disposed, is dried. Drying causes the insulating element 100, and particularly the insulating material 102, to achieve a smooth surface, which provides a wear-resistant surface and also reduces the adhesion of dirt particles. Since the adhesion of dirt particles, such as dust, increases the risk of electrical breakdown, another advantage in electrical protection can be achieved.

[0098] In other (not shown) embodiments of the isolation element 100, one or more features and / or advantages of the embodiments mentioned above may be arbitrarily combined with each other. For example, in the isolation element 100 Figure 1 In the embodiments shown, it is also possible to... Figure 7 The seventh embodiment shown has an additional insulating material 102 comprising an alternative additive 104b provided on the upper side 106.

[0099] Explanation of reference numerals in the attached figures

[0100] 100 isolation elements

[0101] 102 Insulation Material

[0102] Additives 104a and 104b

[0103] The upper side of the 106 isolation element

[0104] The lower side of the 108 isolation element

[0105] 110 Shell Components

[0106] 112 Outer side of shell component

[0107] 114 Inner side of shell component

[0108] 116 provides isolation elements

[0109] 118 Adding and / or applying insulating material to the interior or surface of the insulating element.

[0110] 120 Dry Insulation Element

Claims

1. An insulating element (100), particularly for insulating housing components of an energy storage device or energy converter, such as for an electrically driven motor vehicle, wherein the insulating element (100) comprises or is formed of an insulating material, wherein the insulating material (102) comprises or is formed of at least one additive (104a, 104b), particularly for improving the heat resistance and / or electrical and / or mechanical resistance of the insulating element (100).

2. The insulating element (100) according to claim 1, wherein the insulating element (100) comprises insulating paper or is configured as insulating paper.

3. The insulating element (100) according to claim 1 or 2, characterized in that, Its thickness is in the range of 0.2 mm to 2 mm, preferably in the range of 0.5 mm to 1.5 mm, and especially 1 mm.

4. The insulating element (100) according to any one of the preceding claims, wherein the insulating element (100) comprises or is formed wholly or partially of the insulating material (102).

5. The insulating element (100) according to any one of the preceding claims, wherein the at least one (104a, 104b) comprises or is formed of an expanding material.

6. The insulating element (100) according to any one of the preceding claims, wherein the at least one additive (104a, 104b) comprises an insulating material, in particular an aerogel, or is formed from an insulating material, in particular an aerogel.

7. The insulating element (100) according to any one of the preceding claims, wherein the at least one additive (104a, 104b) comprises or is formed of nonwoven fabric and / or fiber.

8. The insulating element (100) according to any one of the preceding claims, wherein the at least one additive (104a, 104b) comprises or is formed of ceramic particles.

9. A method for manufacturing an insulating element (100), the insulating element being particularly an insulating element according to any one of claims 1 to 8, the method comprising the following steps: - Provide (116) isolation elements (100); - Add and / or apply (118) the insulating material (102) to the interior or surface of the insulating element (100); - Dry (120) the insulating element (100).

10. The method of claim 9, wherein the insulating material (102) is wholly or partially added to the interior of the insulating element (100) and / or the insulating material (102) is wholly or partially applied to the surface of the insulating element (100).

11. The method of claim 9, wherein at least one additive (104a, 104b) is mixed into the insulating material (102), or the insulating material (102) is at least one additive (104a, 104b).

12. A housing member (110), particularly for an energy storage device or energy converter, such as for an electrically driven motor vehicle, wherein an insulating element (100) is mounted, particularly adhered, to the inner (114) and / or outer (112) side of the housing member (110), the insulating element being particularly the insulating element according to any one of the preceding claims.

13. The housing member (110) according to claim 12, wherein the insulating element (100) is wholly or partially mounted, in particular adhered to, the inner side (114) and / or the outer side (112) of the housing member (110).

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