Water-based polyurethane foams and methods of forming same

Abstract

The subject patent application relates to a water-based polyurethane foam material that can include a polyurethane mixture component and a flame retardant component. The water-based polyurethane foam material can have a 40% compressive force (FTC) rating of at least about 1.5 MPa and no greater than about 3.0 MPa. The water-based polyurethane foam material can further have a stress relaxation rate of at least about 10% and no greater than about 25%.

Description

Technical Field

[0001] This disclosure relates to polyurethane foam and methods for forming the same, and more specifically, to polyurethane foam having an excellent flame retardancy rating and methods for forming the same. Background Technology

[0002] Polyurethane foam is widely used in construction, transportation, and electronics applications. However, these polyurethane foams often possess specific properties that make them prone to certain safety issues. For example, due to their inherent chemical properties (i.e., the "-NH-COO- groups" in polyurethane foam result in a lower decomposition temperature compared to many other polymers) and physical properties (i.e., the low density of polyurethane during combustion leads to severe dripping, and the porous structure promotes oxygen and heat transfer), these polyurethane foams are generally prone to rapid ignition. Therefore, polyurethane foam formulations with improved safety properties are desirable. Summary of the Invention

[0003] According to a first aspect, a water-based polyurethane foam material is capable of comprising a polyurethane mixture component and a flame retardant component. The water-based polyurethane foam material is capable of having a 40% compressive strength (FTC) rating of at least about 1.5 MPa and not more than about 3.0 MPa. The water-based polyurethane foam material is further capable of having a stress relaxation rate of at least about 10% and not more than about 25%.

[0004] According to another aspect, the compression pad can comprise a water-based polyurethane foam material. This water-based polyurethane foam material can comprise a polyurethane blend component and a flame retardant component. The compression pad can have a thickness of no more than about 300 micrometers. The compression pad can further have a 40% compressive strength (FTC) rating of at least about 1.5 MPa and no more than about 3.0 MPa. The compression pad can further have a stress relaxation rate of at least about 10% and no more than about 25%.

[0005] According to another aspect, the solid-state battery compression pad can comprise a water-based polyurethane foam material. This water-based polyurethane foam material can comprise a polyurethane blend component and a flame retardant component. The solid-state battery compression pad can have a thickness of no more than about 300 micrometers. The solid-state battery compression pad can further have a 40% compressive strength (FTC) rating of at least about 1.5 MPa and no more than about 3.0 MPa. The solid-state battery compression pad can further have a stress relaxation rate of at least about 10% and no more than about 25%.

[0006] According to another aspect, the solid-state battery can include at least two individual cell units and at least one compression pad located between the at least two individual cell units. The compression pad can include a water-based polyurethane foam material. The water-based polyurethane foam material can include a polyurethane blend component and a flame retardant component. The compression pad can have a thickness of no more than about 300 micrometers. The compression pad can further have a 40% compressive strength (FTC) rating of at least about 1.5 MPa and no more than about 3.0 MPa. The compression pad can further have a stress relaxation rate of at least about 10% and no more than about 25%.

[0007] According to another aspect, a method for forming water-based polyurethane foam can include providing a raw material mixture and forming the water-based polyurethane foam from the raw material mixture. The raw material mixture can include a raw polyurethane mixture component and a flame retardant component. The water-based polyurethane foam material can have a 40% compressive strength (FTC) rating of at least about 1.5 MPa and not more than about 3.0 MPa. The water-based polyurethane foam material can further have a stress relaxation rate of at least about 10% and not more than about 25%. Attached Figure Description

[0008] The implementation scheme is illustrated by way of example and is not limited to the accompanying drawings.

[0009] Figure 1 Includes a figure illustrating a water-based polyurethane foam forming method 100 according to an embodiment described herein; and

[0010] Figure 2a and Figure 2b Includes images demonstrating various aspects of the test methods used for elongation testing.

[0011] Those skilled in the art will recognize that the elements in the accompanying drawings are shown for simplicity and clarity and are not necessarily drawn to scale. Detailed Implementation

[0012] The following discussion will focus on specific implementations and schemes of the teaching content. Detailed descriptions are provided to aid in the depiction of certain schemes and should not be construed as limiting the scope or applicability of this disclosure or teaching content. It should be understood that other schemes may be used based on the disclosure and teaching provided herein.

[0013] The terms “comprising,” “including,” “having,” or any other variations thereof are intended to cover non-exclusive inclusion. For example, a method, article, or apparatus that includes a list of features is not necessarily limited to those features, but can include other features not expressly listed or inherent to such a method, article, or apparatus. Furthermore, unless expressly stated to the contrary, “or” means inclusive or, not exclusive or. For example, conditions A or B are satisfied by either: A is true (or exists) and B is false (or does not exist); A is false (or does not exist) and B is true (or exists); and both A and B are true (or exist).

[0014] Furthermore, the terms "an" or "a" are used to describe the elements and components described herein. This is done merely for convenience and to give a general meaning to the scope of the invention. This description should be understood to include one, at least one, or the singular includes the plural and vice versa, unless explicitly stated otherwise. For example, when a single item is described herein, more than one item can be used instead of a single item. Similarly, in the case of more than one item described herein, a single item can be used instead of the more than one item.

[0015] The embodiments described herein generally relate to water-based polyurethane foam and methods for forming the same. More specifically, the embodiments described herein relate to water-based polyurethane foam with excellent compressibility and flame retardancy, and methods for forming the same.

[0016] For illustrative purposes, Figure 1 The diagram includes an illustration of a water-based polyurethane foam forming method 100 according to a specific embodiment described herein. This water-based polyurethane foam forming method 100 can include a first step 110 of providing a raw material mixture and a second step 120 of forming the raw material mixture into a water-based polyurethane foam.

[0017] Referring to step 110, according to a specific implementation scheme, the raw material mixture may include the original polyurethane mixture component and the original flame retardant component.

[0018] According to a specific embodiment, the raw material mixture can include a specific amount of the original polyurethane mixture component. For example, the raw material mixture can have a content of at least about 30% by weight, such as at least about 33% by weight, at least about 35% by weight, at least about 38% by weight, at least about 40% by weight, at least about 43% by weight, at least about 48% by weight, or even at least about 50% by weight of the original polyurethane mixture component, as a percentage of the total weight of the raw material mixture. According to yet other embodiments, the raw material mixture can have a content of no more than about 70% by weight, such as no more than about 65% by weight, no more than about 60% by weight, or even no more than about 55% by weight of the original polyurethane mixture component, as a percentage of the total weight of the raw material mixture. It should be understood that the content of the original polyurethane mixture component in the raw material mixture can be within any range between the aforementioned minimum and maximum values. It should also be understood that the content of the original polyurethane mixture component in the raw material mixture can be any value between the aforementioned minimum and maximum values.

[0019] According to other embodiments, the original polyurethane mixture component may include a first original polyurethane dispersion, which may include a copolymer of polyester material and polycarbonate material.

[0020] According to some further embodiments, the raw material mixture may include a specific amount of a first primary polyurethane dispersion. For example, the raw material mixture may have a content of at least about 10% by weight, such as at least about 11% by weight, at least about 12% by weight, at least about 13% by weight, at least about 14% by weight, at least about 15% by weight, at least about 16% by weight, or even at least about 17% by weight of the first primary polyurethane dispersion, accounting for a percentage of the total weight of the original polyurethane material mixture. According to yet another embodiment, the raw material mixture may have a content of no more than about 30% by weight, such as no more than about 28% by weight, no more than about 25% by weight, or even no more than about 23% by weight of the first primary polyurethane dispersion, accounting for a percentage of the total weight of the original polyurethane material mixture. It should be understood that the content of the first primary polyurethane dispersion in the raw material mixture may be within any range between the aforementioned minimum and maximum values. It should also be understood that the content of the first primary polyurethane dispersion in the raw material mixture may be any value between the aforementioned minimum and maximum values.

[0021] According to some other embodiments, the original polyurethane mixture component may include a second original polyurethane dispersion, which may include a polycarbonate material.

[0022] According to some further embodiments, the raw material mixture may include a specific amount of a second primary polyurethane dispersion. For example, the raw material mixture may have a content of at least about 20% by weight, such as at least about 21% by weight, at least about 22% by weight, at least about 23% by weight, at least about 24% by weight, at least about 25% by weight, at least about 26% by weight, or even at least about 27% by weight of the second primary polyurethane dispersion, based on the total weight of the raw material mixture. According to yet another embodiment, the raw material mixture may have a content of no more than about 40% by weight, such as no more than about 38% by weight, no more than about 35% by weight, or even no more than about 33% by weight of the second primary polyurethane dispersion, based on the total weight of the raw material mixture. It should be understood that the content of the second primary polyurethane dispersion in the raw material mixture may be within any range of the aforementioned minimum and maximum values. It should also be understood that the content of the second primary polyurethane dispersion in the raw material mixture may be any value between any of the aforementioned minimum and maximum values.

[0023] According to some other implementations, the original flame retardant component may include an aqueous solution, which may include a phosphorus-based flame retardant.

[0024] According to specific embodiments, the raw material mixture can include a specific amount of the original flame retardant component. For example, the raw material mixture can have a content of at least about 10% by weight, such as at least about 13% by weight, at least about 15% by weight, at least about 18% by weight, at least about 20% by weight, at least about 23% by weight, at least about 25% by weight, at least about 28% by weight, or even at least about 30% by weight of the original flame retardant component, accounting for no more than about 40% by weight, such as no more than about 38% by weight, at least about 35% by weight, or even no more than about 33% by weight of the original flame retardant component, accounting for no more than about 40% by weight of the total weight of the raw material mixture. It should be understood that the content of the original flame retardant component in the raw material mixture can be within any range between the aforementioned minimum and maximum values. It should also be understood that the content of the original flame retardant component in the raw material mixture can be any value between the aforementioned minimum and maximum values.

[0025] According to some further embodiments, the raw material mixture may further include a primary first cell stabilizer. According to some further embodiments, the primary first cell stabilizer may include a salt of fatty acids and NH4+.

[0026] According to a specific embodiment, the raw material mixture can include a specific amount of the original first cell stabilizer. For example, the raw material mixture can have an original first cell stabilizer content of at least about 0.5% by weight, such as at least about 0.8% by weight, at least about 1.0% by weight, at least about 1.3% by weight, or even at least about 1.5% by weight, based on the total weight of the raw material mixture. According to yet other embodiments, the raw material mixture can have an original first cell stabilizer content of no more than about 4.0% by weight, such as no more than about 3.8% by weight, no more than about 3.5% by weight, or even no more than about 3.3% by weight, based on the total weight of the raw material mixture. It should be understood that the original first cell stabilizer content in the raw material mixture can be within any range between the aforementioned minimum and maximum values. It should also be understood that the original first cell stabilizer content in the raw material mixture can be any value between the aforementioned minimum and maximum values.

[0027] According to some further embodiments, the raw material mixture may further include a primary second cell stabilizer. According to some further embodiments, the primary second cell stabilizer may include a salt of sodium and sulfosuccinic acid.

[0028] According to a specific embodiment, the raw material mixture can include a specific amount of the primary second cell stabilizer. For example, the raw material mixture can have an amount of at least about 0.5% by weight, such as at least about 0.8% by weight, at least about 1.0% by weight, at least about 1.3% by weight, or even at least about 1.5% by weight, of the primary second cell stabilizer as a percentage of the total weight of the raw material mixture. According to yet other embodiments, the raw material mixture can have an amount of no more than about 4.0% by weight, such as no more than about 3.8% by weight, no more than about 3.5% by weight, or even no more than about 3.3% by weight, of the primary second cell stabilizer as a percentage of the total weight of the raw material mixture. It should be understood that the amount of the primary second cell stabilizer in the raw material mixture can be within any range of the aforementioned minimum and maximum values. It should also be understood that the amount of the primary second cell stabilizer in the raw material mixture can be any value between any of the aforementioned minimum and maximum values.

[0029] According to some further embodiments, the raw material mixture may further include an initial crosslinking agent. According to some further embodiments, the initial crosslinking agent may include a capped aliphatic polyisocyanate.

[0030] According to a specific embodiment, the raw material mixture can include a specific amount of the original crosslinking agent. For example, the raw material mixture can have an original crosslinking agent content of at least about 2.5% by weight, such as at least about 3.0% by weight, at least about 3.5% by weight, at least about 4.0% by weight, or even at least about 4.5% by weight, based on the total weight of the raw material mixture. According to yet other embodiments, the raw material mixture can have an original crosslinking agent content of no more than about 10.0% by weight, such as no more than about 9.5% by weight, no more than about 9.0% by weight, or even no more than about 8.5% by weight, based on the total weight of the raw material mixture. It should be understood that the original crosslinking agent content in the raw material mixture can be within any range between the aforementioned minimum and maximum values. It should also be understood that the original crosslinking agent content in the raw material mixture can be any value between the aforementioned minimum and maximum values.

[0031] According to some further embodiments, the raw material mixture may further include primary pigments. According to some further embodiments, the primary pigments may include water-based pigments.

[0032] According to a specific embodiment, the raw material mixture can include a specific amount of primary pigment. For example, the raw material mixture can have a primary pigment content of at least about 1.0% by weight, such as at least about 1.5% by weight, at least about 2.0% by weight, at least about 2.5% by weight, or even at least about 3.0% by weight, of the total weight of the raw material mixture. According to yet other embodiments, the raw material mixture can have a primary pigment content of no more than about 10.0% by weight, such as no more than about 9.5% by weight, no more than about 9.0% by weight, or even no more than about 8.5% by weight, of the total weight of the raw material mixture. It should be understood that the primary pigment content in the raw material mixture can be within any range between the aforementioned minimum and maximum values. It should also be understood that the primary pigment content in the raw material mixture can be any value between the aforementioned minimum and maximum values.

[0033] According to some further embodiments, the raw material mixture may further include an original thickener. According to some further embodiments, the original thickener may include an acrylic polymer.

[0034] According to a specific embodiment, the raw material mixture can include a specific amount of primary thickener. For example, the raw material mixture can have a primary thickener content of at least about 0.02% by weight, such as at least about 0.05% by weight, at least about 0.5% by weight, at least about 1.0% by weight, or even at least about 1.5% by weight, based on the total weight of the raw material mixture. According to yet other embodiments, the raw material mixture can have a primary thickener content of no more than about 10.0% by weight, such as no more than about 9.0% by weight, at least about 8.0% by weight, or even no more than about 7.0% by weight, based on the total weight of the raw material mixture. It should be understood that the content of primary thickener in the raw material mixture can be within any range between the aforementioned minimum and maximum values. It should also be understood that the content of primary thickener in the raw material mixture can be any value between any of the aforementioned minimum and maximum values.

[0035] According to some other embodiments, forming a polyurethane foam from a raw material mixture can include foaming the raw material mixture to form a foamed material mixture. According to still other embodiments, forming a water-based polyurethane foam from a raw material mixture can further include curing the foamed material mixture to form a water-based polyurethane foam.

[0036] Now, referring to the water-based polyurethane foam formed according to the embodiments described herein, the water-based polyurethane foam may include a polyurethane mixture component and a flame retardant component.

[0037] According to a specific embodiment, water-based polyurethane foam can possess a specific 40% FTC (Free Tightness) (FTC). According to the specific embodiment, 40% FTC can be measured according to an FTC testing method in which: 1) the foam sample is cut into 1-inch × 1-inch sheets and stacked in multiple layers (i.e., sheets) to prepare a sample with a thickness of 4 mm to 6 mm; 2) the sample is vertically compressed using an Instron at an initial force of 0.01 MPa and a compression rate of 0.01 mm / s; and 3) FTC (y-axis) and strain (x-axis) curves are collected to obtain the FTC value at 40% strain. For the 40% FTC described herein, this value is the average 40% FTC of three samples measured according to the FTC test described herein. According to specific embodiments, water-based polyurethane foam can have a 40% FTC of at least about 1.5 MPa, such as at least about 1.6 MPa, at least about 1.7 MPa, at least about 1.8 MPa, at least about 1.9 MPa, at least about 2.0 MPa, at least about 2.1 MPa, at least about 2.2 MPa, at least about 2.3 MPa, at least about 2.4 MPa, or even at least about 2.5 MPa. According to further embodiments, water-based polyurethane foam can have a 40% FTC of no more than about 3.0 MPa, such as no more than about 2.9 MPa, no more than about 2.8 MPa, no more than about 2.7 MPa, or even no more than about 2.6 MPa. It should be understood that the 40% FTC of water-based polyurethane foam can be within any range between the aforementioned minimum and maximum values. It should also be understood that the 40% FTC of water-based polyurethane foam can be any value between the aforementioned minimum and maximum values.

[0038] According to a specific embodiment, water-based polyurethane foam can possess a specific stress relaxation rate. According to the specific embodiment, the stress relaxation rate can be measured using a stress relaxation test, in which: 1) a foam sample is cut into 1-inch × 1-inch pieces to form a specimen; 2) a 10mm diameter stainless steel compression probe of a texture analyzer is used to vertically compress the specimen until a force of 2.5kg is reached, which is considered the starting point; 3) from the starting point, the specimen is further compressed at a compression rate of 10µm / s to 40µm; 4) the stress at this location is recorded as F1; 5) the probe is held at this location for 60 seconds; and 6) the stress is recorded again as F2. The stress relaxation rate is equal to (F1-F2) / F1. For the purposes of this stress relaxation rate description, this value is the average stress relaxation rate of three specimens measured according to the stress relaxation rate test described herein. According to specific embodiments, the water-based polyurethane foam can have a stress relaxation rate of at least about 13.0%, such as at least about 13.25%, at least about 13.5%, at least about 13.75%, at least about 14.0%, at least about 14.25%, at least about 14.5%, at least about 14.75%, at least about 15.0%, at least about 15.25%, or even at least about 15.5%. According to further embodiments, the water-based polyurethane foam can have a stress relaxation rate of no more than about 20.0%, such as no more than about 19.75%, no more than about 19.5%, no more than about 19.0%, no more than about 18.5%, no more than about 18.25%, no more than about 18.0%, no more than about 17.75%, no more than about 17.5%, no more than about 17.25%, or even no more than about 17.0%. It should be understood that the stress relaxation rate of water-based polyurethane foam can be within any range between the aforementioned minimum and maximum values. It should also be understood that the stress relaxation rate of water-based polyurethane foam can be any value between the aforementioned minimum and maximum values.

[0039] According to some further embodiments, water-based polyurethane foam can have a UL94 VTM-2 flammability rating. According to yet another embodiment, water-based polyurethane foam can have a UL94 VTM-0 flammability rating.

[0040] According to a specific embodiment, the water-based polyurethane foam can have a specific elongation (5 mm / min). According to a specific embodiment, the elongation (5 mm / min) can be measured by an elongation test, in which 1) the foam sample is cut into a dumbbell shape with a width of 5 mm and a length of 22 mm (e.g., Figure 2a (as shown) to form a sample, 2) as shown Figure 2bThe clamps of the texture analyzer shown are used to hold the sample in a dumbbell shape at the upper and lower positions. 3) The upper clamp is raised to stretch the sample at a speed of 5 mm / min, and 4) the elongation at break of the sample is recorded. For the purposes of this description, the elongation is the average elongation of three samples measured according to the elongation test described herein. According to a specific embodiment, the water-based polyurethane foam can have an elongation (5 mm / min) of at least about 150%, such as at least about 160%, at least about 170%, at least about 180%, at least about 190%, at least about 200%, at least about 210%, at least about 220%, at least about 230%, at least about 240%, or even at least about 250%. It should be understood that the elongation (5 mm / min) of the water-based polyurethane foam can be within any of the above values. It should also be understood that the elongation (5 mm / min) of the water-based polyurethane foam can be any value between any of the above values.

[0041] According to a specific embodiment, the water-based polyurethane foam can have a specific elongation (100 mm / min). According to a specific embodiment, the elongation (100 mm / min) can be measured by an elongation test, in which 1) the foam sample is cut into a dumbbell shape with a width of 5 mm and a length of 22 mm (e.g., Figure 2a (as shown) to form a sample, 2) as shown Figure 2b The clamps of the texture analyzer shown are used to hold the sample in a dumbbell shape at the upper and lower positions. 3) The upper clamp is raised to stretch the sample at a speed of 100 mm / min, and 4) the elongation at break of the sample is recorded. For the purposes of this description, the elongation is the average elongation of three samples measured according to the elongation test described herein. According to a specific embodiment, water-based polyurethane foam can have an elongation (100 mm / min) of at least about 75%, such as at least about 100%, at least about 125%, at least about 130%, at least about 140%, at least about 150%, at least about 160%, at least about 170%, at least about 180%, at least about 190%, or even at least about 200%. It should be understood that the elongation (100 mm / min) of water-based polyurethane foam can be within any of the above values. It should also be understood that the elongation (100 mm / min) of water-based polyurethane foam can be any value among the above values.

[0042] According to a specific embodiment, the water-based polyurethane foam can have a specific density. According to the specific embodiment, the density can be measured by: 1) cutting the foam sample into 10cm × 10cm pieces to form a sample; 2) measuring the thickness of the sample at 5 points and taking the average to determine the sample thickness; 3) weighing the sample using a balance; and 4) calculating the density as weight / (thickness * length * width). According to the specific embodiment, the water-based polyurethane foam can have a density of at least approximately 350 kg / m³. 3 Such as at least about 360 kg / m 3 Or at least approximately 370 kg / m 3 Or at least approximately 380 kg / m 3 Or at least approximately 390 kg / m 3 Or at least approximately 400 kg / m 3 Or at least approximately 410 kg / m 3 Or at least approximately 420 kg / m 3 Or at least approximately 430 kg / m 3 Or at least approximately 440 kg / m 3 Or even at least about 450 kg / m 3 The density. According to some further embodiments, water-based polyurethane foam can have a density of no more than approximately 550 kg / m³. 3 Such as not greater than approximately 540 kg / m 3 Or no more than approximately 530 kg / m 3 Or no more than approximately 520 kg / m 3 Or no more than approximately 510 kg / m 3 or no more than approximately 500 kg / m 3 or no more than approximately 490 kg / m 3 or no more than approximately 480 kg / m 3 or no more than approximately 470 kg / m 3 Or even no more than approximately 460 kg / m 3 The density. It should be understood that the density of water-based polyurethane foam can be within any range between the aforementioned minimum and maximum values. It should also be understood that the density of water-based polyurethane foam can be any value between the aforementioned minimum and maximum values.

[0043] According to specific embodiments, water-based polyurethane foam materials can include a specific content of polyurethane mixture components. For example, water-based polyurethane foam materials can have a content of at least about 30% by weight, such as at least about 33% by weight, at least about 35% by weight, at least about 38% by weight, at least about 40% by weight, at least about 43% by weight, at least about 48% by weight, or even at least about 50% by weight, of the polyurethane mixture component as a percentage of the total weight of the water-based polyurethane foam material. According to still other embodiments, water-based polyurethane foam materials can have a content of no more than about 70% by weight, such as no more than about 65% by weight, no more than about 60% by weight, or even no more than about 55% by weight, of the polyurethane mixture component as a percentage of the total weight of the water-based polyurethane foam material. It should be understood that the content of the polyurethane mixture component in the water-based polyurethane foam material can be within any range between the aforementioned minimum and maximum values. It should also be understood that the content of the polyurethane mixture component in the water-based polyurethane foam material can be any value between the aforementioned minimum and maximum values.

[0044] According to other embodiments, the polyurethane mixture component may include a first polyurethane dispersion, which may include a copolymer of polyester material and polycarbonate material.

[0045] According to some further embodiments, the polyurethane material mixture can include a specific amount of a first polyurethane dispersion. For example, the polyurethane material mixture can have a content of at least about 10% by weight, such as at least about 11% by weight, at least about 12% by weight, at least about 13% by weight, at least about 14% by weight, at least about 15% by weight, at least about 16% by weight, or even at least about 17% by weight of the first polyurethane dispersion as a percentage of the total weight of the polyurethane material mixture. According to yet another embodiment, the polyurethane material mixture can have a content of no more than about 30% by weight, such as no more than about 28% by weight, no more than about 25% by weight, or even no more than about 23% by weight of the first polyurethane dispersion as a percentage of the total weight of the polyurethane material mixture. It should be understood that the content of the first polyurethane dispersion in the polyurethane material mixture can be within any range of the aforementioned minimum and maximum values. It should also be understood that the content of the first polyurethane dispersion in the polyurethane material mixture can be any value between any of the aforementioned minimum and maximum values.

[0046] According to some other embodiments, the polyurethane mixture component may include a second polyurethane dispersion, which may include a polycarbonate material.

[0047] According to some further embodiments, the water-based polyurethane foam material can include a specific content of a second polyurethane dispersion. For example, the water-based polyurethane foam material can have a content of at least about 20% by weight, such as at least about 21% by weight, at least about 22% by weight, at least about 23% by weight, at least about 24% by weight, at least about 25% by weight, at least about 26% by weight, or even at least about 27% by weight of the second polyurethane dispersion as a percentage of the total weight of the water-based polyurethane foam material. According to yet another embodiment, the water-based polyurethane foam material can have a content of no more than about 40% by weight, such as no more than about 38% by weight, no more than about 35% by weight, or even no more than about 33% by weight of the second polyurethane dispersion as a percentage of the total weight of the water-based polyurethane foam material. It should be understood that the content of the second polyurethane dispersion in the water-based polyurethane foam material can be within any range between the aforementioned minimum and maximum values. It should also be understood that the content of the second polyurethane dispersion in the water-based polyurethane foam material can be any value between the aforementioned minimum and maximum values.

[0048] According to some other embodiments, the flame retardant component may include an aqueous solution, which may include a phosphorus-based flame retardant.

[0049] According to specific embodiments, water-based polyurethane foam materials can include a specific content of flame retardant components. For example, water-based polyurethane foam materials can have a content of at least about 10% by weight, such as at least about 13% by weight, at least about 15% by weight, at least about 18% by weight, at least about 20% by weight, at least about 23% by weight, at least about 25% by weight, at least about 28% by weight, or even at least about 30% by weight, of the total weight of the water-based polyurethane foam material. According to still other embodiments, water-based polyurethane foam materials can have a content of no more than about 40% by weight, such as no more than about 38% by weight, no more than about 35% by weight, or even no more than about 33% by weight, of the total weight of the water-based polyurethane foam material. It should be understood that the content of flame retardant components in water-based polyurethane foam materials can be within any range between the aforementioned minimum and maximum values. It should also be understood that the content of flame retardant components in water-based polyurethane foam materials can be any value between the aforementioned minimum and maximum values.

[0050] According to some further embodiments, the water-based polyurethane foam material may further include a first cell stabilizer. According to some further embodiments, the first cell stabilizer may include a salt of fatty acids and NH4+.

[0051] According to specific embodiments, the water-based polyurethane foam material can include a specific amount of a first cell stabilizer. For example, the water-based polyurethane foam material can have a first cell stabilizer content of at least about 0.5% by weight, such as at least about 0.8% by weight, at least about 1.0% by weight, at least about 1.3% by weight, or even at least about 1.5% by weight, of the total weight of the water-based polyurethane foam material. According to still other embodiments, the water-based polyurethane foam material can have a first cell stabilizer content of no more than about 4.0% by weight, such as no more than about 3.8% by weight, no more than about 3.5% by weight, or even no more than about 3.3% by weight, of the total weight of the water-based polyurethane foam material. It should be understood that the content of the first cell stabilizer in the water-based polyurethane foam material can be within any range between the aforementioned minimum and maximum values. It should also be understood that the content of the first cell stabilizer in the water-based polyurethane foam material can be any value between the aforementioned minimum and maximum values.

[0052] According to some further embodiments, the water-based polyurethane foam material may further include a second cell stabilizer. According to some further embodiments, the second cell stabilizer may include a salt of sodium and sulfosuccinic acid.

[0053] According to specific embodiments, the water-based polyurethane foam material can include a specific amount of a second cell stabilizer. For example, the water-based polyurethane foam material can have a content of at least about 0.5% by weight, such as at least about 0.8% by weight, at least about 1.0% by weight, at least about 1.3% by weight, or even at least about 1.5% by weight, of the second cell stabilizer as a percentage of the total weight of the water-based polyurethane foam material. According to still other embodiments, the water-based polyurethane foam material can have a content of no more than about 4.0% by weight, such as no more than about 3.8% by weight, no more than about 3.5% by weight, or even no more than about 3.3% by weight, of the second cell stabilizer as a percentage of the total weight of the water-based polyurethane foam material. It should be understood that the content of the second cell stabilizer in the water-based polyurethane foam material can be within any range between the aforementioned minimum and maximum values. It should also be understood that the content of the second cell stabilizer in the water-based polyurethane foam material can be any value between the aforementioned minimum and maximum values.

[0054] According to some further embodiments, the water-based polyurethane foam material may further include a crosslinking agent. According to some further embodiments, the crosslinking agent may include end-capped aliphatic polyisocyanates.

[0055] According to specific embodiments, water-based polyurethane foam materials can include a specific content of crosslinking agent. For example, water-based polyurethane foam materials can have a crosslinking agent content of at least about 2.5% by weight, such as at least about 3.0% by weight, at least about 3.5% by weight, at least about 4.0% by weight, or even at least about 4.5% by weight, of the total weight of the water-based polyurethane foam material. According to still other embodiments, water-based polyurethane foam materials can have a crosslinking agent content of no more than about 10.0% by weight, such as no more than about 9.5% by weight, no more than about 9.0% by weight, or even no more than about 8.5% by weight, of the total weight of the water-based polyurethane foam material. It should be understood that the crosslinking agent content in the water-based polyurethane foam material can be within any range between the aforementioned minimum and maximum values. It should also be understood that the crosslinking agent content in the water-based polyurethane foam material can be any value between the aforementioned minimum and maximum values.

[0056] According to some further embodiments, the water-based polyurethane foam material may further include pigments. According to some further embodiments, the pigments may include water-based pigments.

[0057] According to specific embodiments, water-based polyurethane foam materials can include a specific amount of pigment. For example, water-based polyurethane foam materials can have a pigment content of at least about 1.0% by weight, such as at least about 1.5% by weight, at least about 2.0% by weight, at least about 2.5% by weight, or even at least about 3.0% by weight, of the total weight of the water-based polyurethane foam material. According to still other embodiments, water-based polyurethane foam materials can have a pigment content of no more than about 10.0% by weight, such as no more than about 9.5% by weight, no more than about 9.0% by weight, or even no more than about 8.5% by weight, of the total weight of the water-based polyurethane foam material. It should be understood that the pigment content in the water-based polyurethane foam material can be within any range between the aforementioned minimum and maximum values. It should also be understood that the pigment content in the water-based polyurethane foam material can be any value between the aforementioned minimum and maximum values.

[0058] According to some further embodiments, the water-based polyurethane foam material may further include a thickener. According to some further embodiments, the thickener may include an acrylic polymer.

[0059] According to specific embodiments, water-based polyurethane foam materials can include a specific amount of thickener. For example, water-based polyurethane foam materials can have a thickener content of at least about 0.02% by weight, such as at least about 0.05% by weight, at least about 0.5% by weight, at least about 1.0% by weight, or even at least about 1.5% by weight, of the total weight of the water-based polyurethane foam material. According to still other embodiments, water-based polyurethane foam materials can have a thickener content of no more than about 10.0% by weight, such as no more than about 9.0% by weight, no more than about 8.0% by weight, or even no more than about 7.0% by weight, of the total weight of the water-based polyurethane foam material. It should be understood that the thickener content in the water-based polyurethane foam material can be within any range between the aforementioned minimum and maximum values. It should also be understood that the thickener content in the water-based polyurethane foam material can be any value between the aforementioned minimum and maximum values.

[0060] Referring now to the specific use of the polyurethane foam formed according to the embodiments described herein, a particular embodiment may include a compression pad comprising polyurethane foam. It should be understood that the polyurethane foam of the compression pad can be formed according to any embodiment described herein. It should also be understood that the polyurethane foam of the battery compression pad can include any of the components described in any embodiment described herein. It should also be understood that the polyurethane foam of the compression pad can have any of the properties described in the embodiments described herein.

[0061] According to a specific embodiment, the compression pad can have a specific 40% FTC (Free Tightness of Compression). According to a specific embodiment, the 40% FTC can be measured according to an FTC test method in which: 1) a foam sample is cut into 1-inch × 1-inch sheets and stacked in multiple layers (i.e., sheets) to prepare a sample with a thickness of 4 mm to 6 mm; 2) the sample is vertically compressed using an Instron with an initial force of 0.01 MPa and a compression rate of 0.01 mm / s; and 3) FTC (y-axis) and strain (x-axis) curves are collected to obtain the FTC value at 40% strain. For the 40% FTC described herein, this value is the average 40% FTC of three samples measured according to the FTC test described herein. According to specific embodiments, the compression pad can have a 40% FTC of at least about 1.5 MPa, such as at least about 1.6 MPa, at least about 1.7 MPa, at least about 1.8 MPa, at least about 1.9 MPa, at least about 2.0 MPa, at least about 2.1 MPa, at least about 2.2 MPa, at least about 2.3 MPa, at least about 2.4 MPa, or even at least about 2.5 MPa. According to further embodiments, the compression pad can have a 40% FTC of no more than about 3.0 MPa, such as no more than about 2.9 MPa, no more than about 2.8 MPa, no more than about 2.7 MPa, or even no more than about 2.6 MPa. It should be understood that the 40% FTC of the compression pad can be within any range between the aforementioned minimum and maximum values. It should also be understood that the 40% FTC of the compression pad can be any value between any of the aforementioned minimum and maximum values.

[0062] According to a specific embodiment, the compression pad can have a specific stress relaxation rate. According to a specific embodiment, the stress relaxation rate can be measured according to a stress relaxation test, in which: 1) a foam sample is cut into 1-inch × 1-inch pieces to form a sample; 2) a stainless steel compression probe with a diameter of 10 mm of a texture analyzer is used to vertically compress the sample until a force of 2.5 kg is reached, which is considered the starting point; 3) from the starting point, the sample is further compressed to 40 μm at a compression rate of 10 μm / s; 4) the stress at this position is recorded as F1; 5) the probe is held at this position for 60 seconds; and 6) the stress is recorded again as F2. The stress relaxation rate is equal to (F1 - F2) / F1. For the purposes of this stress relaxation rate description, this value is the average stress relaxation rate of three samples measured according to the stress relaxation rate test described herein. According to specific embodiments, the compression pad can have a stress relaxation rate of at least about 13.0%, such as at least about 13.25%, at least about 13.5%, at least about 13.75%, at least about 14.0%, at least about 14.25%, at least about 14.5%, at least about 14.75%, at least about 15.0%, at least about 15.25%, or even at least about 15.5%. According to further embodiments, the compression pad can have a stress relaxation rate of no more than about 20.0%, such as no more than about 19.75%, no more than about 19.5%, no more than about 19.0%, no more than about 18.5%, no more than about 18.25%, no more than about 18.0%, no more than about 17.75%, no more than about 17.5%, no more than about 17.25%, or even no more than about 17.0%. It should be understood that the stress relaxation rate of the compression pad can be within any range between the aforementioned minimum and maximum values. It should also be understood that the stress relaxation rate of the compression pad can be any value between the aforementioned minimum and maximum values.

[0063] According to some further embodiments, the compression pad can have a UL94 VTM-2 flammability rating. According to yet another embodiment, the compression pad can have a UL94 VTM-0 flammability rating.

[0064] According to a specific embodiment, the compression pad can have a specific elongation (5 mm / min). According to a specific embodiment, the elongation (5 mm / min) can be measured according to an elongation test, in which 1) the foam sample is cut into a dumbbell shape with a width of 5 mm and a length of 22 mm (e.g., Figure 2a (as shown) to form a sample, 2) as shown Figure 2bThe clamps of the texture analyzer shown are used to hold the sample in a dumbbell shape at the upper and lower positions. 3) The upper clamp is raised to stretch the sample at a speed of 5 mm / min, and 4) the elongation at fracture is recorded. For the purposes of this description, the elongation is the average elongation of three samples measured according to the elongation test described herein. According to a specific embodiment, the compression pad can have an elongation (5 mm / min) of at least about 150%, such as at least about 160%, at least about 170%, at least about 180%, at least about 190%, at least about 200%, at least about 210%, at least about 220%, at least about 230%, at least about 240%, or even at least about 250%. It should be understood that the elongation (5 mm / min) of the compression pad can be within any of the above values. It should also be understood that the elongation (5 mm / min) of the compression pad can be any value between any of the above values.

[0065] According to a specific embodiment, the compression pad can have a specific elongation (100 mm / min). According to a specific embodiment, the elongation (100 mm / min) can be measured according to an elongation test, in which 1) the foam sample is cut into a dumbbell shape with a width of 5 mm and a length of 22 mm (e.g., ...). Figure 2a (as shown) to form a sample, 2) as shown Figure 2b The clamps of the texture analyzer shown are used to hold the sample in a dumbbell shape at the upper and lower positions. 3) The upper clamp is raised to stretch the sample at a speed of 100 mm / min, and 4) the elongation at fracture of the sample is recorded. For the purposes of this description, the elongation is the average elongation of three samples measured according to the elongation test described herein. According to a specific embodiment, the compression pad can have an elongation (100 mm / min) of at least about 75%, such as at least about 100%, at least about 125%, at least about 130%, at least about 140%, at least about 150%, at least about 160%, at least about 170%, at least about 180%, at least about 190%, or even at least about 200%. It should be understood that the elongation (100 mm / min) of the compression pad can be within any of the above values. It should also be understood that the elongation (100 mm / min) of the compression pad can be any value between any of the above values.

[0066] According to a specific embodiment, the compression pad can have a specific density. According to the specific embodiment, the density can be measured by: 1) cutting a foam sample into 10cm × 10cm pieces to form a sample; 2) measuring the thickness of the sample at 5 points and taking the average to determine the thickness of the sample; 3) weighing the sample using a balance; and 4) calculating the density as weight / (thickness * length * width). According to the specific embodiment, the compression pad can have at least approximately 350 kg / m³. 3 Such as at least about 360 kg / m 3 Or at least approximately 370 kg / m 3 Or at least approximately 380 kg / m 3 Or at least approximately 390 kg / m 3 Or at least approximately 400 kg / m 3 Or at least approximately 410 kg / m 3 Or at least approximately 420 kg / m 3 Or at least approximately 430 kg / m 3 Or at least approximately 440 kg / m 3 Or even at least about 450 kg / m 3 The density. According to some further embodiments, the compression pad can have a density not exceeding approximately 550 kg / m³. 3 Such as not greater than approximately 540 kg / m 3 Or no more than approximately 530 kg / m 3 Or no more than approximately 520 kg / m 3 Or no more than approximately 510 kg / m 3 or no more than approximately 500 kg / m 3 or no more than approximately 490 kg / m 3 or no more than approximately 480 kg / m 3 or no more than approximately 470 kg / m 3 Or even no more than approximately 460 kg / m 3 The density of the compression pad. It should be understood that the density of the compression pad can be within any range between the aforementioned minimum and maximum values. It should also be understood that the density of the compression pad can be any value between the aforementioned minimum and maximum values.

[0067] Referring now to another specific application of the polyurethane foam formed according to the embodiments described herein, a specific embodiment may include a solid-state battery compression pad, which may include polyurethane foam. It should be understood that the polyurethane foam of the solid-state battery compression pad can be formed according to any embodiment described herein. It should also be understood that the polyurethane foam of the solid-state battery compression pad can include any of the components described in any embodiment described herein. It should also be understood that the polyurethane foam of the solid-state battery compression pad can have any of the properties described in the embodiments described herein.

[0068] According to a specific embodiment, the solid-state battery compression pad can have a specific 40% FTC (Free Tightness). According to the specific embodiment, the 40% FTC can be measured according to an FTC test method in which: 1) a foam sample is cut into 1-inch × 1-inch sheets and stacked in multiple layers (i.e., sheets) to prepare a sample with a thickness of 4 mm to 6 mm; 2) the sample is vertically compressed using an Instron with an initial force of 0.01 MPa and a compression rate of 0.01 mm / s; and 3) FTC (y-axis) and strain (x-axis) curves are compiled to obtain the FTC value at 40% strain. For the 40% FTC described herein, this value is the average 40% FTC of three samples measured according to the FTC test described herein. According to specific embodiments, the solid-state battery compression pad can have a 40% FTC of at least about 1.5 MPa, such as at least about 1.6 MPa, at least about 1.7 MPa, at least about 1.8 MPa, at least about 1.9 MPa, at least about 2.0 MPa, at least about 2.1 MPa, at least about 2.2 MPa, at least about 2.3 MPa, at least about 2.4 MPa, or even at least about 2.5 MPa. According to further embodiments, the solid-state battery compression pad can have a 40% FTC of no more than about 3.0 MPa, such as no more than about 2.9 MPa, no more than about 2.8 MPa, no more than about 2.7 MPa, or even no more than about 2.6 MPa. It should be understood that the 40% FTC of the solid-state battery compression pad can be within any range of the aforementioned minimum and maximum values. It should also be understood that the 40% FTC of the solid-state battery compression pad can be any value between any of the aforementioned minimum and maximum values.

[0069] According to a specific embodiment, the solid-state battery compression pad can have a specific stress relaxation rate. According to the specific embodiment, the stress relaxation rate can be measured according to a stress relaxation test, in which: 1) a foam sample is cut into 1-inch × 1-inch pieces to form a sample; 2) a stainless steel compression probe with a diameter of 10 mm from a texture analyzer is used to vertically compress the sample until a force of 2.5 kg is reached, which is considered the starting point; 3) from the starting point, the sample is further compressed to 40 μm at a compression rate of 10 μm / s; 4) the stress at this position is recorded as F1; 5) the probe is held at this position for 60 seconds; and 6) the stress is recorded again as F2. The stress relaxation rate is equal to (F1 - F2) / F1. For the purposes of this document, this value is the average stress relaxation rate of three samples measured according to the FTC test described herein. According to specific embodiments, the solid-state battery compression pad can have a stress relaxation rate of at least about 13.0%, such as at least about 13.25%, at least about 13.5%, at least about 13.75%, at least about 14.0%, at least about 14.25%, at least about 14.5%, at least about 14.75%, at least about 15.0%, at least about 15.25%, or even at least about 15.5%. According to further embodiments, the solid-state battery compression pad can have a stress relaxation rate of no more than about 20.0%, such as no more than about 19.75%, no more than about 19.5%, no more than about 19.0%, no more than about 18.5%, no more than about 18.25%, no more than about 18.0%, no more than about 17.75%, no more than about 17.5%, no more than about 17.25%, or even no more than about 17.0%. It should be understood that the stress relaxation rate of the solid-state battery compression pad can be within any range between the aforementioned minimum and maximum values. It should also be understood that the stress relaxation rate of the solid-state battery compression pad can be any value between the aforementioned minimum and maximum values.

[0070] According to some further embodiments, the solid-state battery compression pad can have a UL94 VTM-2 flammability rating. According to yet another embodiment, the solid-state battery compression pad can have a UL94 VTM-0 flammability rating.

[0071] According to a specific embodiment, the solid-state battery compression pad can have a specific elongation (5 mm / min). According to a specific embodiment, the elongation (5 mm / min) can be measured according to an elongation test, in which 1) the foam sample is cut into a dumbbell shape with a width of 5 mm and a length of 22 mm (e.g., Figure 2a (as shown) to form a sample, 2) as shown Figure 2bThe clamps of the texture analyzer shown are used to hold the sample in a dumbbell shape at the upper and lower positions. 3) The upper clamp is raised to stretch the sample at a speed of 5 mm / min, and 4) the elongation at fracture of the sample is recorded. For the purposes of this description, the elongation is the average elongation of three samples measured according to the elongation test described herein. According to a specific embodiment, the solid-state battery compression pad can have an elongation (5 mm / min) of at least about 150%, such as at least about 160%, at least about 170%, at least about 180%, at least about 190%, at least about 200%, at least about 210%, at least about 220%, at least about 230%, at least about 240%, or even at least about 250%. It should be understood that the elongation (5 mm / min) of the solid-state battery compression pad can be within any of the above values. It should also be understood that the elongation (5 mm / min) of the solid-state battery compression pad can be any value between any of the above values.

[0072] According to a specific embodiment, the solid-state battery compression pad can have a specific elongation (100 mm / min). According to a specific embodiment, the elongation (100 mm / min) can be measured by an elongation test, in which 1) the foam sample is cut into a dumbbell shape with a width of 5 mm and a length of 22 mm (e.g., ...). Figure 2a (as shown) to form a sample, 2) as shown Figure 2b The clamps of the texture analyzer shown are used to hold the specimen in a dumbbell shape at the upper and lower positions. 3) The upper clamp is raised to stretch the sample at a speed of 100 mm / min, and 4) the elongation at fracture is recorded. For the purposes of this description, the elongation is the average elongation of three samples measured according to the elongation test described herein. According to a specific embodiment, the solid-state battery compression pad can have an elongation (100 mm / min) of at least about 75%, such as at least about 100%, at least about 125%, at least about 130%, at least about 140%, at least about 150%, at least about 160%, at least about 170%, at least about 180%, at least about 190%, or even at least about 200%. It should be understood that the elongation (100 mm / min) of the solid-state battery compression pad can be within any of the above values. It should also be understood that the elongation (100 mm / min) of the solid-state battery compression pad can be any value among the above values.

[0073] According to a specific embodiment, the solid-state battery compression pad can have a specific density. According to the specific embodiment, the density can be measured by: 1) cutting a foam sample into 10cm × 10cm pieces to form a sample; 2) measuring the thickness of the sample at 5 points and taking the average to determine the sample thickness; 3) weighing the sample using a balance; and 4) calculating the density as weight / (thickness * length * width). According to the specific embodiment, the solid-state battery compression pad can have at least approximately 350 kg / m³. 3 Such as at least about 360 kg / m 3 Or at least approximately 370 kg / m 3 Or at least approximately 380 kg / m 3 Or at least approximately 390 kg / m 3 Or at least approximately 400 kg / m 3 Or at least approximately 410 kg / m 3 Or at least approximately 420 kg / m 3 Or at least approximately 430 kg / m 3 Or at least approximately 440 kg / m 3 Or even at least about 450 kg / m 3 The density. According to some further embodiments, the solid-state battery compression pad can have a density of no more than approximately 550 kg / m³. 3 Such as not greater than approximately 540 kg / m 3 Or no more than approximately 530 kg / m 3 Or no more than approximately 520 kg / m 3 Or no more than approximately 510 kg / m 3 or no more than approximately 500 kg / m 3 or no more than approximately 490 kg / m 3 or no more than approximately 480 kg / m 3 or no more than approximately 470 kg / m 3 Or even no more than approximately 460 kg / m 3 The density of the solid-state battery compression pad. It should be understood that the density of the solid-state battery compression pad can be within any range between the aforementioned minimum and maximum values. It should also be understood that the density of the solid-state battery compression pad can be any value between the aforementioned minimum and maximum values.

[0074] Many different aspects and embodiments are possible. Some of these aspects and embodiments are described herein. After reading this specification, those skilled in the art will recognize that those aspects and embodiments are merely illustrative and do not limit the scope of the invention. Embodiments can be implemented according to any one or more of the embodiments listed below.

[0075] Implementation Scheme 1. A water-based polyurethane foam material comprising: a polyurethane mixture component and a flame retardant component, wherein the water-based polyurethane foam material has a stress relaxation rate of at least about 1.5 MPa and not more than about 3.0 MPa of 40%; and wherein the water-based polyurethane foam material has a stress relaxation rate of at least about 10% and not more than about 25%.

[0076] Implementation Scheme 2. A compression pad comprising: a water-based polyurethane foam material, wherein the water-based polyurethane foam material comprises: a polyurethane mixture component and a flame retardant component, wherein the compression pad has a thickness of not more than about 300 micrometers, wherein the compression pad has a stress relaxation rate of at least about 1.5 MPa and not more than about 3.0 MPa of 40%; and wherein the compression pad has a stress relaxation rate of at least about 10% and not more than about 25%.

[0077] Implementation Scheme 3. A solid-state battery compression pad comprising: a water-based polyurethane foam material, wherein the water-based polyurethane foam material comprises: a polyurethane mixture component and a flame retardant component, wherein the compression pad has a thickness of not more than about 300 micrometers, wherein the compression pad has a stress relaxation rate of at least about 1.5 MPa and not more than about 3.0 MPa of 40%; and wherein the compression pad has a stress relaxation rate of at least about 10% and not more than about 25%.

[0078] Implementation Scheme 4. A solid-state battery comprising: at least two individual battery cells and at least one compression pad located between the at least two individual battery cells, wherein the compression pad comprises: a water-based polyurethane foam material, wherein the water-based polyurethane foam material comprises: a polyurethane mixture component and a flame retardant component, wherein the compression pad has a thickness of not more than about 300 micrometers, wherein the compression pad has a stress relaxation rate of at least about 1.5 MPa and not more than about 3.0 MPa of 40%; and wherein the compression pad has a stress relaxation rate of at least about 10% and not more than about 25%.

[0079] Implementation Scheme 5. A water-based polyurethane foam material, a compression pad, a solid-state battery compression pad, or a solid-state battery according to any one of Implementation Schemes 1, 2, 3, and 4, wherein the polyurethane foam material has a 40% FTC of at least about 1.6 MPa.

[0080] Implementation Scheme 6. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 1, 2, 3, and 4, wherein the polyurethane foam material has an FTC of not more than about 2.9 MPa and 40%.

[0081] Implementation Scheme 7. A water-based polyurethane foam material, a compression pad, a solid-state battery compression pad, or a solid-state battery according to any one of Implementation Schemes 1, 2, 3, and 4, wherein the polyurethane foam material has a stress relaxation rate of at least about 13%.

[0082] Implementation Scheme 8. A water-based polyurethane foam material, a compression pad, a solid-state battery compression pad, or a solid-state battery according to any one of Implementation Schemes 1, 2, 3, and 4, wherein the polyurethane foam material has a stress relaxation rate of not more than about 20%.

[0083] Implementation Scheme 9. A water-based polyurethane foam material, a compression pad, a solid-state battery compression pad, or a solid-state battery according to any one of Implementation Schemes 1, 2, 3, and 4, wherein the polyurethane foam material has a UL94 VTM-2 flammability rating.

[0084] Implementation Scheme 10. A water-based polyurethane foam material, a compression pad, a solid-state battery compression pad, or a solid-state battery according to any one of Implementation Schemes 1, 2, 3, and 4, wherein the polyurethane foam material has a UL94 VTM-0 flammability rating.

[0085] Implementation Scheme 11. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 1, 2, 3, and 4, wherein the polyurethane foam material has an elongation of at least about 150% (5 mm / min).

[0086] Implementation Scheme 12. A water-based polyurethane foam material, a compression pad, a solid-state battery compression pad, or a solid-state battery according to any one of Implementation Schemes 1, 2, 3, and 4, wherein the polyurethane foam material has an elongation of at least about 75% (100 mm / min).

[0087] Implementation Scheme 13. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 1, 2, 3, and 4, wherein the polyurethane foam material has a density of at least about 350 kg / m³. 3 The density.

[0088] Implementation Scheme 14. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 1, 2, 3, and 4, wherein the polyurethane foam material has a strength of not more than approximately 550 kg / m³. 3 The density.

[0089] Implementation Scheme 15. A compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 2, 3, and 4, wherein the compression pad has a 40% FTC of at least about 1.6 MPa.

[0090] Implementation Scheme 16. A compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 2, 3, and 4, wherein the compression pad has an FTC of no more than about 2.9 MPa at 40%.

[0091] Implementation Scheme 17. A compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 2, 3, and 4, wherein the compression pad has a stress relaxation rate of at least about 13%.

[0092] Implementation Scheme 18. A compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 2, 3, and 4, wherein the compression pad has a stress relaxation rate of not more than about 20%.

[0093] Implementation Scheme 19. A compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 2, 3, and 4, wherein the compression pad has a UL94 VTM-2 flammability rating.

[0094] Implementation Scheme 20. A compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 2, 3, and 4, wherein the compression pad has a UL94 VTM-0 flammability rating.

[0095] Implementation Scheme 21. A compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 2, 3, and 4, wherein the compression pad has an elongation of at least about 150% (5 mm / min).

[0096] Implementation Scheme 22. A compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 2, 3, and 4, wherein the compression pad has an elongation of at least about 75% (100 mm / min).

[0097] Implementation Scheme 23. A compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 2, 3, and 4, wherein the compression pad has a strength of at least about 350 kg / m³. 3 The density.

[0098] Implementation Scheme 24. A compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 2, 3, and 4, wherein the compression pad has a strength of not more than about 550 kg / m³. 3 The density.

[0099] Implementation Scheme 25. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to any one of Implementation Schemes 1, 2, 3, and 4, wherein the polyurethane mixture component comprises: a first polyurethane dispersion comprising a copolymer of a polyester material and a polycarbonate material, and a second polyurethane dispersion comprising a polycarbonate material.

[0100] Implementation Scheme 26. The water-based polyurethane foam material, compression pad, solid-state battery compression pad or solid-state battery according to Implementation Scheme 25, wherein the water-based polyurethane foam material component has a first polyurethane dispersion content of at least 10% by weight of the total weight of the water-based polyurethane foam material component.

[0101] Implementation Scheme 27. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 25, wherein the water-based polyurethane foam material component has a first polyurethane dispersion content of not more than about 30% by weight of the total weight of the water-based polyurethane foam material component.

[0102] Implementation Scheme 28. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 25, wherein the water-based polyurethane foam material component has a second polyurethane dispersion content of at least 20% by weight of the total weight of the water-based polyurethane foam material component.

[0103] Implementation Scheme 29. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 25, wherein the water-based polyurethane foam material component has a second polyurethane dispersion content of not more than about 40% by weight of the total weight of the water-based polyurethane foam material component.

[0104] Implementation Scheme 30. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 25, wherein the water-based polyurethane foam material further includes a first cell stabilizer.

[0105] Implementation Scheme 31. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 30, wherein the water-based polyurethane foam material component has a first cell stabilizer content of at least 0.5% by weight of the total weight of the water-based polyurethane foam material component.

[0106] Implementation Scheme 32. The water-based polyurethane foam material, compression pad, solid-state battery compression pad or solid-state battery according to Implementation Scheme 30, wherein the water-based polyurethane foam material component has a first cell stabilizer content of not more than about 4.0% by weight of the total weight of the water-based polyurethane foam material component.

[0107] Implementation Scheme 33. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 30, wherein the first cell stabilizer comprises a salt of fatty acid and NH4+.

[0108] Implementation Scheme 34. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 25, wherein the water-based polyurethane foam material further includes a second cell stabilizer.

[0109] Implementation Scheme 35. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 34, wherein the water-based polyurethane foam material component has a second cell stabilizer content of at least 0.5% by weight of the total weight of the water-based polyurethane foam material component.

[0110] Implementation Scheme 36. The water-based polyurethane foam material, compression pad, solid-state battery compression pad or solid-state battery according to Implementation Scheme 34, wherein the water-based polyurethane foam material component has a second cell stabilizer content of not more than about 4.0% by weight of the total weight of the water-based polyurethane foam material component.

[0111] Implementation Scheme 37. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 34, wherein the second cell stabilizer comprises a salt of sodium and sulfosuccinic acid.

[0112] Implementation Scheme 38. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 25, wherein the water-based polyurethane foam material further includes a crosslinking agent.

[0113] Implementation Scheme 39. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 38, wherein the water-based polyurethane foam material component has a crosslinking agent content of at least 2.5% by weight of the total weight of the water-based polyurethane foam material component.

[0114] Implementation Scheme 40. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 38, wherein the water-based polyurethane foam material component has a crosslinking agent content of not more than about 10.0% by weight of the total weight of the water-based polyurethane foam material component.

[0115] Implementation Scheme 41. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 38, wherein the crosslinking agent comprises a capped aliphatic polyisocyanate.

[0116] Implementation Scheme 42. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 25, wherein the water-based polyurethane foam material further includes pigments.

[0117] Implementation Scheme 43. The water-based polyurethane foam material, compression pad, solid-state battery compression pad or solid-state battery according to Implementation Scheme 42, wherein the water-based polyurethane foam material component has a pigment content of at least 1.0% by weight of the total weight of the water-based polyurethane foam material component.

[0118] Implementation Scheme 44. The water-based polyurethane foam material, compression pad, solid-state battery compression pad or solid-state battery according to Implementation Scheme 42, wherein the water-based polyurethane foam material component has a pigment content of not more than about 10.0% by weight of the total weight of the water-based polyurethane foam material component.

[0119] Implementation Scheme 45. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 42, wherein the pigment includes a water-based pigment.

[0120] Implementation Scheme 46. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 25, wherein the water-based polyurethane foam material further includes a thickener.

[0121] Implementation Scheme 47. The water-based polyurethane foam material, compression pad, solid-state battery compression pad or solid-state battery according to Implementation Scheme 46, wherein the water-based polyurethane foam material component has a thickener content of at least 0.02% by weight of the total weight of the water-based polyurethane foam material component.

[0122] Implementation Scheme 48. The water-based polyurethane foam material, compression pad, solid-state battery compression pad or solid-state battery according to Implementation Scheme 46, wherein the water-based polyurethane foam material component has a thickener content of not more than about 10.0% by weight of the total weight of the water-based polyurethane foam material component.

[0123] Implementation Scheme 49. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 46, wherein the thickener comprises an acrylic polymer.

[0124] Implementation Scheme 50. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 25, wherein the water-based polyurethane foam material further includes a flame retardant component.

[0125] Implementation Scheme 51. A water-based polyurethane foam material, compression pad, solid-state battery compression pad or solid-state battery according to Implementation Scheme 25, wherein the water-based polyurethane foam material component has a flame retardant component content of at least 10.0% by weight of the total weight of the water-based polyurethane foam material component.

[0126] Implementation Scheme 52. A water-based polyurethane foam material, compression pad, solid-state battery compression pad or solid-state battery according to Implementation Scheme 25, wherein the water-based polyurethane foam material component has a flame retardant component content of not more than about 40.0% by weight of the total weight of the water-based polyurethane foam material component.

[0127] Implementation Scheme 53. A water-based polyurethane foam material, compression pad, solid-state battery compression pad, or solid-state battery according to Implementation Scheme 25, wherein the flame retardant component includes an aqueous solution, the aqueous solution including a phosphorus-based flame retardant.

[0128] Implementation Scheme 54. A method for forming a water-based polyurethane foam, wherein the method comprises: providing a raw material mixture comprising: a raw polyurethane mixture component and a raw flame retardant component; and forming the raw polyurethane mixture into a water-based polyurethane foam, wherein the water-based polyurethane foam material has a stress relaxation rate of at least about 1.5 MPa and not more than about 3.0 MPa of 40%; and wherein the water-based polyurethane foam material has a stress relaxation rate of at least about 10% and not more than about 25%.

[0129] Example

[0130] The concepts described herein will be further illustrated in the following embodiments, which do not limit the scope of the invention as set forth in the claims.

[0131] Example 1

[0132] Sample water-based polyurethane foam S1 was formed according to the implementation scheme described herein. The composition of sample water-based polyurethane foam S1 is summarized in Table 1 below.

[0133] Table 1 - Sample Foam Composition

[0134]

[0135] A water-based polyurethane foam sample is formed by mixing all liquid components until the liquid phase is homogeneous. Then, any filler is added to the liquid mixture. The combined mixture is then mixed until a homogeneous composition is achieved. Finally, the mixture is cured in an oven at 70°C–150°C for several minutes.

[0136] Each sample of polyurethane foam was tested to determine density, 40% FTC, stress relaxation rate, and elongation.

[0137] Table 2 - Properties of Polyurethane Foam

[0138]

[0139] Note that not all activities described above in the general description or embodiments are required; some specific activities may not be required, and one or more additional activities may be provided in addition to those described. Furthermore, the order in which the activities are listed is not necessarily the order in which they are performed.

[0140] The benefits, other advantages, and solutions to the problems have been described above with respect to specific embodiments. However, these benefits, advantages, solutions to the problems, and any features that could cause any benefit, advantage, or solution to occur or become more significant should not be construed as key, necessary, or essential features of any or all claims.

[0141] The description and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of various embodiments. The description and illustrations are not intended as an exhaustive and comprehensive description of all elements and features of devices and systems using the structures or methods described herein. Individual embodiments can also be provided in combination in separate embodiments, and conversely, for brevity, various features described in the context of a single embodiment may also be provided individually or in any sub-combination. Furthermore, references to values ​​stated in the scope include every value within that scope. Many other embodiments will become apparent to those skilled in the art only after reading this specification. Other embodiments may be used and other embodiments may be derived from this disclosure, enabling structural substitutions, logical substitutions, or other changes without departing from the scope of the invention. Therefore, this disclosure should be considered illustrative rather than restrictive.

Claims

1. A water-based polyurethane foam material, comprising: Polyurethane mixture components, and Flame retardant components, The water-based polyurethane foam material has a FTC of at least about 1.5 MPa and no more than about 3.0 MPa of 40%; and The water-based polyurethane foam material described therein has a stress relaxation rate of at least about 10% and no more than about 25%.

2. A compression pad, comprising: Water-based polyurethane foam materials The water-based polyurethane foam material includes: Polyurethane mixture components, and Flame retardant components, The compression pad described herein has a thickness of no more than approximately 300 micrometers. The compression pad has a free pressure of at least about 1.5 MPa and no more than about 3.0 MPa, with a free pressure of 40%; and The compression pad described therein has a stress relaxation rate of at least about 10% and no more than about 25%.

3. A solid-state battery compression pad, comprising: Water-based polyurethane foam materials The water-based polyurethane foam material includes: Polyurethane mixture components, and Flame retardant components, The compression pad described herein has a thickness of no more than approximately 300 micrometers. The compression pad has a free pressure of at least about 1.5 MPa and no more than about 3.0 MPa, with a free pressure of 40%; and The compression pad described therein has a stress relaxation rate of at least about 10% and no more than about 25%.

4. The water-based polyurethane foam material, compression pad, and solid-state battery compression pad according to any one of claims 1, 2, and 3, wherein the polyurethane foam material has a 40% FTC of at least about 1.6 MPa.

5. The water-based polyurethane foam material, compression pad, and solid-state battery compression pad according to any one of claims 1, 2, and 3, wherein the polyurethane foam material has a 40% FTC of not more than about 2.9 MPa.

6. The water-based polyurethane foam material, compression pad, and solid-state battery compression pad according to any one of claims 1, 2, and 3, wherein the polyurethane foam material has a stress relaxation rate of at least about 13%.

7. The water-based polyurethane foam material, compression pad, and solid-state battery compression pad according to any one of claims 1, 2, and 3, wherein the polyurethane foam material has a stress relaxation rate of not more than about 20%.

8. The water-based polyurethane foam material, compression pad, and solid-state battery compression pad according to any one of claims 1, 2, and 3, wherein the polyurethane foam material has a UL94 VTM-2 flammability rating.

9. The water-based polyurethane foam material, compression pad, and solid-state battery compression pad according to any one of claims 1, 2, and 3, wherein the polyurethane foam material has a UL94 VTM-0 flammability rating.

10. The water-based polyurethane foam material, compression pad, and solid-state battery compression pad according to any one of claims 1, 2, and 3, wherein the polyurethane foam material has an elongation of at least about 150% (5 mm / min).

11. The water-based polyurethane foam material, compression pad, and solid-state battery compression pad according to any one of claims 1, 2, and 3, wherein the polyurethane foam material has an elongation of at least about 75% (100 mm / min).

12. The water-based polyurethane foam material, compression pad, and solid-state battery compression pad according to any one of claims 1, 2, and 3, wherein the polyurethane foam material has a density of at least about 350 kg / m³. 3 The density.

13. The water-based polyurethane foam material, compression pad, and solid-state battery compression pad according to any one of claims 1, 2, and 3, wherein the polyurethane foam material has a strength of not more than about 550 kg / m³. 3 The density.

14. The water-based polyurethane foam material, compression pad, and solid-state battery compression pad according to any one of claims 1, 2, and 3, wherein the compression pad has a 40% FTC of at least about 1.6 MPa.

15. The water-based polyurethane foam material, compression pad, and solid-state battery compression pad according to any one of claims 1, 2, and 3, wherein the compression pad has a 40% FTC of not more than about 2.9 MPa.

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