Fire resistant composition and molded article using the same

Abstract

The invention relates to a fire resistant composition and molded articles using the same, the fire resistant composition comprising about 20 to 55 wt% of a base resin comprising a polyketone, a fibrous filler, a non-fibrous filler, and a flame retardant. The fibrous filler can have a length / diameter ratio greater than 3. The composition can optionally comprise additives such as antioxidants or process stabilizers. Possible applications include heat generating devices, battery casings, and other high temperature environments.

Description

Technical Field

[0001] This invention relates to a refractory composition and a molded article using the refractory composition. Background Technology

[0002] Recently, the popularity of electric vehicles as a replacement for internal combustion engine vehicles has increased significantly. To increase the driving range and output of electric vehicles, research is underway on the integration of batteries or battery modules with improved fire resistance and per unit area of ​​the battery pack.

[0003] Battery cells within a battery pack may burn due to factors such as manufacturing defects, external pressure, impact, and overcharging. This can cause heat to be transferred to adjacent battery cells or modules, leading to thermal instability of the entire battery pack.

[0004] If such thermal instability occurs, the casing or structure of the battery module may melt due to temperatures of 1000°C or higher, and may further accelerate the thermal instability of adjacent battery modules.

[0005] To prevent thermal instability in battery packs, not only is the safety design of the battery pack considered crucial, but the fire resistance and thermal insulation performance of the components that make up the battery modules and battery packs are also considered crucial.

[0006] Glass fiber-filled polypropylene resin and injection-molded articles using it can be used for the housings of battery modules and battery packs, but may not be able to maintain the structure and rigidity of the components in the event of thermal instability. Summary of the Invention

[0007] The present invention was completed in consideration of the problems encountered in related technologies, and the present invention provides a composition and a molded article using the composition, the composition being able to delay the acceleration of thermal instability and impart fire resistance when thermal instability occurs in heating devices, battery packs, etc.

[0008] The present invention also provides a composition and a molded article using the composition, wherein the composition retains good durability, maintains its structure and rigidity, and has insulating properties after being subjected to blowtorch and gravel tests at a temperature of about 1200°C.

[0009] The invention will be clearly understood from the following description, and the invention can be implemented by the means and combinations thereof described in the claims.

[0010] Some embodiments of the present invention provide a refractory composition comprising 20% ​​to 55% by weight of a base resin, fibrous fillers, non-fibrous fillers, and a flame retardant, wherein the base resin comprises polyketide, and wherein the length / diameter ratio of the fibrous fillers is greater than 3.

[0011] Refractory compositions can be applied to components of heating devices.

[0012] The amount of fiber filler can be from about 30% to 60% by weight, based on the total weight of the composition.

[0013] The amount of non-fibrous filler can be from about 6% to 15% by weight, based on the total weight of the composition.

[0014] The amount of flame retardant can be from about 4% to 20% by weight, based on the total weight of the composition.

[0015] According to ASTM D1238, the melt flow rate of polyketone at 240°C and a load of 2.16 kg can be from 150 g / 10 min to 400 g / 10 min.

[0016] Fiber fillers may include at least one of glass fiber, carbon fiber, basalt fiber and quartz fiber.

[0017] Non-fibrous fillers may include at least one of silica, silicone, alumina, silicon carbide, boron carbide, silicon nitride, zirconium oxide, titanium dioxide, magnesium oxide, aluminosilicate, calcium silicate, and talc.

[0018] Non-fiber fillers may include silica, silicone and alumina.

[0019] In some aspects, the amount of silica may suitably be from about 2% to 5% by weight, the amount of silicone may be from about 2% to 5% by weight, and the amount of alumina may be from about 2% to 5% by weight, based on the total weight of the composition.

[0020] In some aspects, the flame retardant may suitably include one or more phosphate ester agents, such as at least one of triphenyl phosphate, trimethyl phosphate, triethyl phosphate, bisphenol diphenyl phosphate, ammonium polyphosphate, melamine phosphate, melamine pyrophosphate, melamine ammonium cyanurate, melamine polyphosphate, dimethyl diphenyl phosphate, aluminum hydroxide and / or magnesium hydroxide.

[0021] In some aspects, the refractory composition may also suitably contain about 0.5% to 2% by weight of additives, based on the total weight of the composition, said additives including at least one of antioxidants, processing stabilizers or activators.

[0022] In some respects, the base resin may also suitably contain polyamide, and the amount of polyketone is from about 16% to 44% by weight and the amount of polyamide is from about 4% to 11% by weight, based on the total weight of the composition.

[0023] The present invention can provide a molded article manufactured by molding the above-described refractory composition.

[0024] The present invention can provide an energy storage device comprising at least one of a housing manufactured by melting and injection molding the above-described refractory composition and a battery cell or battery module disposed in the housing.

[0025] In some other embodiments, a refractory composition is provided comprising: about 20% to 55% by weight of a base resin, about 30% to 60% by weight of a fiber filler, about 6% to about 15% by weight of a non-fiber filler, and about 4% to 20% by weight of a flame retardant, wherein the base resin comprises polyketone having a melt flow rate of 150 g / 10 min to 400 g / 10 min at 240 °C under a 2.16 kg load according to ASTM D1238, and the fiber filler having a length-to-diameter ratio greater than 3.

[0026] The refractory composition may also contain one or more additives in a total amount of about 0.5% to 2% by weight, wherein the one or more additives are selected from antioxidants, processing stabilizers and activators.

[0027] Non-fibrous fillers may include silica, silicone, and alumina, each in an amount of about 2% to 5% by weight of the total composition.

[0028] The base resin may also contain polyamide. The amount of polyketone may be from about 16% to 40% by weight, and the amount of polyamide may be from about 4% to 11% by weight, respectively, based on the total weight of the composition. Attached Figure Description

[0029] Figure 1 A photograph showing the results of the blowtorch and gravel test in Example 2.

[0030] Figure 2 A photograph showing the results of the blowtorch and gravel tests according to Comparative Example 2 of the test examples. Detailed Implementation

[0031] The above and other objects, features, and advantages of the invention will become clearer from the following preferred embodiments presented in conjunction with the accompanying drawings. However, the invention is not limited to the embodiments disclosed herein and can be modified in various forms. These embodiments are provided to thoroughly explain the invention and to fully convey its spirit to those skilled in the art.

[0032] It will be understood that although terms such as “first,” “second,” etc., may be used herein to describe various elements, these elements are not limited by these terms. These terms are used only to distinguish one element from another. For example, a “first” element discussed below may be referred to as a “second” element without departing from the scope of the invention. Similarly, a “second” element may also be referred to as a “first” element. As used herein, unless the context clearly indicates otherwise, the singular form is intended to include the plural form as well.

[0033] It will also be understood that when the terms "comprising," "including," "having," etc., are used in this specification, they indicate the presence of the stated feature, value, step, operation, element, component, or combination thereof, but do not exclude the presence or addition of one or more other features, values, steps, operations, elements, components, or combinations thereof. Furthermore, it will be understood that when an element (e.g., a layer, film, region, or sheet) is referred to as being "on" another element, it may be directly on the other element, or an intervening element may be present between them. Similarly, when an element (e.g., a layer, film, region, or sheet) is referred to as being "under" another element, it may be directly under the other element, or an intervening element may be present between them.

[0034] In this article, the comma "," can be interpreted as "and" or "or" depending on the context, and the comma can be interpreted as "or" if the element listed by the comma ends with "or".

[0035] It should be understood that the term "vehicle" or "of a vehicle" or other similar terms used herein generally include motor vehicles, such as passenger cars including sport utility vehicles (SUVs), buses, trucks, various commercial vehicles, boats and vessels including various vessels and ships, aircraft, etc., including hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles, and other alternative fuel vehicles (e.g., vehicles derived from non-petroleum fuels). As mentioned herein, a hybrid vehicle is a vehicle with two or more power sources, such as a vehicle that combines gasoline and electric power.

[0036] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used herein, unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “described” are intended to include the plural forms as well. These terms are intended only to distinguish one component from another, and the terms do not limit the characteristics, order, or sequence of the constituent components. As used herein, the term “and / or” includes any and all combinations of one or more of the associated enumerated items. Furthermore, the terms “unit,” “device,” “component,” and “module” described in the specification mean a unit for performing at least one function and operation, and can be implemented by hardware components or software components and combinations thereof.

[0037] Although the exemplary embodiments are described as using multiple units to perform the exemplary process, it should be understood that the exemplary process can also be performed by one or more modules. Furthermore, it should be understood that the term controller / control unit refers to a hardware device that includes a memory and a processor and is specifically programmed to perform the processes described herein. The memory is configured to store the modules, and the processor is specifically configured to execute the modules, thereby performing one or more processes further described below.

[0038] Furthermore, the control logic of this invention can be embodied in a non-transitory computer-readable medium, including executable program instructions that can be executed by a processor, controller, etc. Examples of computer-readable media include, but are not limited to, ROM, RAM, optical disc (CD)-ROM, magnetic tape, floppy disk, flash drive, smart card, and optical data storage device. The computer-readable medium can also be distributed across a network-connected computer system, allowing it to be stored and executed in a distributed manner, for example, via a telematics server or a controller area network (CAN).

[0039] Unless otherwise stated or obvious from the context, as used herein, the term “about” is understood to mean within the normal tolerance range in the field, for example, within 2 standard deviations of the mean. “About” can be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the specified value. All numerical values ​​provided herein are modified by the term “about” unless obvious from the context.

[0040] Unless otherwise stated, all numbers, numerical values, and / or expressions used herein to represent the amounts of components, reaction conditions, polymer compositions, and mixtures should be considered approximate values, including the various uncertainties inherent in the measurement that affect the results, and therefore should be understood to be modified in all cases by the term "about". Furthermore, when numerical ranges are disclosed in this specification, unless otherwise stated, the range is continuous and includes all values ​​from the minimum to the maximum value of the range. Additionally, when the range involves integer values, unless otherwise stated, it includes all integers from the minimum to the maximum value.

[0041] The term “polyketone” in this article refers to a polymer (or copolymer) having repeating ketone groups (-CO-) in the main chain.

[0042] The term "energy storage device" in this article refers to any device or system that houses one or more battery cells or battery modules.

[0043] Refractory Composition

[0044] The refractory composition according to some embodiments of the present invention may comprise 20% to 55% by weight of a base resin, fibrous filler, non-fibrous filler and flame retardant, wherein the base resin comprises polyketide and wherein the length / diameter ratio of the fibrous filler may be greater than 3.

[0045] Refractory compositions can be applied to components of heating devices, and can be applied to components of heating devices that may experience thermal instability at temperatures of 1000°C or higher. For example, refractory compositions can be applied to components of battery modules or battery packs, or to housings.

[0046] The polyketone base resin can be a homopolymer having essentially one repeating unit.

[0047] Polyketides can contain multiple ketone groups and an alkylene group connecting one ketone group and another ketone group, and the alkylene group can have a carbon number from C2 to C5.

[0048] According to ASTM D1238, the melt flow rate of polyketone at 240°C and a load of 2.16 kg can be from 150 g / 10 min to 400 g / 10 min or from 180 g / 10 min to 350 g / 10 min. When the melt flow rate is within the above range, the composition can be given good extrusion and injection molding processability.

[0049] The composition can achieve melt flow rates of 30 g / 10 min to 90 g / 10 min or 46 g / 10 min to 79 g / 10 min at 240 °C and a load of 2.16 kg, according to ASTM D1238. When the melt flow rate is within the above range, the composition can be given good extrusion and injection molding processability.

[0050] The amount of base resin, based on the total weight of the composition, can be from 20% to 55% by weight or from 25% to 50% by weight. If the amount of base resin is less than 20% by weight, the refractory properties may deteriorate. In contrast, if the amount of base resin exceeds 55% by weight, the amount of filler may decrease, which may also lead to a deterioration in refractory properties.

[0051] The amount of fiber filler can be 30% to 60% by weight or 35% to 55% by weight, based on the total weight of the composition. If the amount of fiber filler is less than 30% by weight, the fire resistance may deteriorate, and it may be difficult to maintain the structure and rigidity after blowtorch and gravel tests. In contrast, if the amount of fiber filler exceeds 60% by weight, the extrusion and injection molding processability may deteriorate, and the appearance quality of the molded articles may be worse.

[0052] Fiber packings can have shapes such as elliptical, plate-shaped, etc., with a constant cross-section and a predetermined length, and the average size of the cross-section can correspond to the diameter. The length / diameter ratio of the fiber packing can be greater than 3 and less than 10000 or less than 5000.

[0053] The average diameter of the fiber filler can be from 2 μm to 30 μm or from 5 μm to 20 μm. When its cross-section is within the above range, it can improve dispersibility and effectively supplement mechanical properties (such as impact strength).

[0054] The fiber filler may include at least one of glass fiber, carbon fiber, basalt fiber or quartz fiber, and may include, for example, glass fiber, or may be glass fiber.

[0055] The amount of non-fibrous filler can be from 6% to 15% by weight, based on the total weight of the composition. If the amount of non-fibrous filler is less than 6% by weight, the refractory properties may deteriorate. In contrast, if the amount of non-fibrous filler exceeds 15% by weight, the processability and appearance quality may deteriorate.

[0056] Non-fibrous fillers may be partially in liquid form, or if solid, their aspect ratio may be 3 or less and 1 or greater. The aspect ratio can be defined as the ratio of the maximum length in the maximum cross-section of a solid material to the length perpendicular to that maximum length.

[0057] Non-fibrous fillers may include at least one of the following: silica, silicone, alumina, silicon carbide, boron carbide, silicon nitride, zirconium oxide, titanium dioxide, magnesium oxide, aluminosilicate, calcium silicate, and talc, preferably silica, silicone, and alumina.

[0058] Silica can include particles with a cristobalite structure in silica isotopes and can be used to further improve fire resistance.

[0059] Silicones can be used to improve the flowability and processability of resins, and can also be used to improve the appearance quality of molded products.

[0060] Aluminum and aluminosilicates have good thermal conductivity, so when the composition is applied to components of a heating device, it can sinter in thermally unstable heating devices and form a stable structure.

[0061] In non-fibrous fillers, the particle size of the solid material can be from 10 μm to 100 μm or from 20 μm to 50 μm. Alumina may include first alumina particles with a particle size of 15 μm to 25 μm and second alumina particles with a particle size of 35 μm to 45 μm.

[0062] When the non-fibrous filler comprises silica, silicone, and alumina, the amount of silica, silicone, and alumina, by total weight of the composition, can be 2% to 5% by weight, respectively. If the amount of silica is less than 2% by weight, the refractoriness may deteriorate. In contrast, if the amount of silica exceeds 5% by weight, the processability and appearance quality may deteriorate. If the amount of silicone is less than 2% by weight, the improvement in resin flowability may be insignificant, and the appearance quality of the molded articles may deteriorate. In contrast, if the amount of silicone exceeds 5% by weight, excessive gas may be generated during molding, and gas generation may increase at high temperatures. If the amount of alumina is less than 2% by weight, sintering may not occur uniformly at high temperatures, resulting in deteriorated refractoriness. In contrast, if the amount of alumina exceeds 5% by weight, the resin flowability and processability may deteriorate, leading to poorer appearance quality.

[0063] Flame retardants can be halogen-free flame retardants that contain virtually no halogen elements.

[0064] The amount of flame retardant can be from 4% to 20% by weight or from 5% to 15% by weight. If the amount of flame retardant is less than 4% by weight, the flame retardancy may be insufficient. In contrast, if the amount of flame retardant exceeds 20% by weight, during the fire resistance test, the carbonized material of the molded part may peel off, the carbonized layer may expand, the degree of deformation may be excessive, and it may be difficult to maintain the structure and rigidity.

[0065] Flame retardants may include at least one of the following: triphenyl phosphate, trimethyl phosphate, triethyl phosphate, bisphenol diphenyl phosphate, ammonium polyphosphate, melamine phosphate, melamine pyrophosphate, melamine ammonium phosphate, melamine cyanurate, piperazine polyphosphate, xylyl diphenyl phosphate, aluminum hydroxide, or magnesium hydroxide.

[0066] In addition to polyketones, the base resin may also contain polyamides. Polyamides may include at least one of polyamide 6, polyamide 66, or a polyamide 6 / 66 copolymer.

[0067] When the base resin also contains polyamide, the amount of polyketone can be from 16% to 44% by weight, and the amount of polyamide can be from 4% to 11% by weight, based on the total weight of the composition. Specifically, the amount of polyketone can be from 20% to 40% by weight, and the amount of polyamide can be from 5% to 10% by weight. If the amount of polyamide is less than 4% by weight, the effect on improving appearance quality may not be significant. In contrast, if the amount of polyamide exceeds 11% by weight, the fire resistance may deteriorate.

[0068] The refractory composition may also contain additives, and said additives may include at least one of antioxidants, processing stabilizers, or activators. Antioxidants may include phenolic antioxidants, amine antioxidants, sulfur antioxidants, phosphorus antioxidants, etc., and examples may include brand names such as Irganox, Irgafos, and Tinuvin series. Processing stabilizers may include alcohol compounds, phthalate compounds, fluoropolymers, etc., and alcohol compounds may include polyvinyl alcohol, polyethylene glycol, polypropylene glycol, C10-C25 aliphatic alcohols, etc.

[0069] The amount of additive can be from 0.5% to 2% by weight, based on the total weight of the composition. When the amount of additive added is within the above range, the processability and appearance quality of the molded article can be further improved.

[0070] Molded products

[0071] According to some embodiments of the present invention, molded articles can be produced by molding the above-described refractory composition.

[0072] Molded articles can be produced by methods including, for example, melting a refractory composition and then extruding the molten composition or injection molding the molten composition in a mold.

[0073] Furthermore, molded articles can be produced by methods including, for example, melting a refractory composition, forming an extrudate by extruding the molten composition, and then injection molding the extrudate using an injection molding machine. Therefore, an injection molding machine can be used to melt and injection mold extrudates.

[0074] An extruder can be used to extrude the refractory composition, and the extruder may include a raw material conveying section, a mixing section, and a discharge section connected in sequence. When driving the extruder, the temperature of the conveying section or mixing section can be from 220°C to 250°C, and can be applied without limitation, as long as it is within the temperature range where the base resin (polyketone) has fluidity and does not undergo thermal decomposition.

[0075] Molded parts can be used as components for heating devices, which are devices that may generate heat at temperatures of 1000°C or higher due to thermal instability. Heating devices can be used in, for example, lithium secondary batteries, fuel cells, thermoelectric devices, power conversion devices, internal combustion engines, etc., and can also be used in energy storage devices (e.g., lithium secondary batteries).

[0076] The molded part can be, for example, a housing (decorative material), and the housing can include at least one of a battery module or a battery pack.

[0077] According to ISO 180, the impact strength of molded articles can be 6 kJ / m. 2 Up to 12kJ / m 2 .

[0078] According to ASTM D3638, the PLC level of the comparative tracking index for molded parts can be 0.

[0079] According to UL94, the flame retardancy of molded articles can be rated V-0.

[0080] In the following UL 2596 torch and gravel test (Modern MS940-02), the surface of a specimen with a predetermined area made by molding may crack after 10 or more cycles, while the surface of the specimen will not crack after 8 or fewer cycles.

[0081] [UL 2596 Blowtorch and Gravel Test]

[0082] The molded specimen was made into a sample with an area of ​​200 mm × 200 mm and a thickness of 2 mm. The specimen was then subjected to the following cycle: each cycle consisted of being exposed to a flame at 1200 °C for 15 seconds at a distance of 60 mm from the specimen surface, followed by being exposed to a flame at 1200 °C and gravel (particles) with an average diameter of 120 μm at a rate of 0.6 g / s for 5 seconds, in order to evaluate the number of cycles required for the specimen surface to crack.

[0083] Energy storage devices

[0084] An energy storage device according to some embodiments of the present invention may include at least one of a housing manufactured by melting and injection molding a refractory composition and a battery cell or battery module disposed in the housing.

[0085] A battery cell typically includes a cathode material, an anode material, and a conductive material in contact with the electrode materials, and may include a separator and an electrolyte solution or solid electrolyte inserted between the spaced electrode materials.

[0086] Battery cells can be cylindrical, prismatic, pouch-shaped, etc.

[0087] A battery module may include multiple battery cells and may also include a controller configured to manage the heat or stability of the battery cells.

[0088] A better understanding of the present invention can be obtained through the following embodiments and comparative embodiments. However, these embodiments should not be construed as limiting the technical spirit of the present invention.

[0089] Example 1

[0090] Prepare a composition having the following components in the following amounts (wt%).

[0091] (A1) 35% by weight of polyketone base resin, wherein the polyketone base resin has a melt flow rate of 200 g / 10 min at 240 °C and 2.16 kg load according to ASTM D1238.

[0092] (B1) 50% by weight of glass fiber, the glass fiber having a cross-sectional diameter of 10 μm and a length of 8 mm;

[0093] (B2) 3% by weight of silicon dioxide, wherein the silicon dioxide has an average particle size of 30 μm and a cristobalite crystal structure;

[0094] (B3) 3% by weight of low molecular weight (Mw: 5000) silicone resin;

[0095] (B4) 3% by weight of alumina, wherein the average particle size of the alumina is 30 μm;

[0096] (C) 5% by weight of melamine phosphate as a flame retardant;

[0097] (D) 1% by weight of additives, said additives comprising phenolic antioxidants (Irganox1098), phosphorus antioxidants (PEP-36), and processing stabilizers (E-Wax, cetearyl alcohol, polysorbate) in a weight ratio of 1:1:1.

[0098] The composition is melt-kneaded using a twin-screw extruder to produce extrudates in pellet form. Therefore, the temperature of the extruder's feed section is 230°C to 240°C, the temperature of the mixing section is 230°C to 240°C, the temperature of the discharge section is 240°C, and the RPM of the extrusion screw is 200.

[0099] The resulting pellet extrudate is dried in an oven at 60°C and then produced into injection molded products using an injection molding machine.

[0100] Examples 2-4 and Comparative Examples 1-7

[0101] The corresponding injection-molded articles are produced by preparing a composition having the amounts (wt%) of the components shown in Tables 1 and 2 below instead of the composition of Example 1, and then performing the same molding process as in Example 1.

[0102] (A2) Polyamide 6

[0103] (A3) Polypropylene, wherein the polypropylene has a melt flow rate of 50 g / 10 min at 230 °C and a load of 2.16 kg, according to ASTM D1238.

[0104] [Table 1]

[0105] category Example 1 Example 2 Example 3 Example 4 A1 Polyketone 35 30 25 28 A2 polyamide - 5 10 5 B1 glass fiber 50 50 50 55 B2 silicon dioxide 3 3 3 2 B3 Silicone 3 3 3 2 B4 aluminum oxide 3 3 3 2 C flame retardant 5 5 5 5 D Additives 1 1 1 1

[0106] Unit: weight %

[0107] [Table 2]

[0108]

[0109]

[0110] Unit: weight %

[0111] Test Implementation Examples - Property Measurement

[0112] The properties of the molded articles prepared in the examples and comparative examples were measured by the following methods, and the results are shown in Tables 3 and 4 below.

[0113] 1) Melt flow rate

[0114] Measurements were performed according to ASTM D1238 at 240°C and 2.16 kg. When the highest-volume component in the base resin is polypropylene or polyamide, measurements were performed at 230°C and 2.16 kg.

[0115] 2) Impact strength

[0116] Measurements were taken according to ISO 180.

[0117] 3) Comparative Tracking Index (CTI)

[0118] Measurements were taken according to ASTM D3638 and the PLC rating (0-5) was displayed.

[0119] 4) Appearance quality

[0120] The surface appearance of the molded article (sample) was observed using a microscope with a magnification of 1000× and rated as excellent, good or poor.

[0121] 5) Flame retardancy

[0122] Measurements were performed according to the UL94 test method.

[0123] 6) Blowtorch and gravel

[0124] According to UL 2596 (Hyundai MS940-02), the molded specimen is made into a sample with an area of ​​200 mm × 200 mm and a thickness of 2 mm. The specimen is then subjected to the following cycle: each cycle consists of being exposed to a flame at 1200°C for 15 seconds at a distance of 60 mm from the specimen surface, followed by being exposed to a flame at 1200°C and gravel (particles) with an average diameter of 120 μm at a rate of 0.6 g / s for 5 seconds, to evaluate the number of cycles required for the specimen surface to break.

[0125] After the test, photos were taken of Example 2 and Comparative Example 2, and the comparison results are shown in the image. Figure 1 , Figure 2 And in Table 5 below.

[0126] [Table 3]

[0127]

[0128] [Table 4]

[0129]

[0130] [Table 5]

[0131]

[0132] Referring to these tables, Comparative Examples 1 and 2 (which contain polypropylene as the main component of the base resin and do not contain polyketone) showed extremely low durability after torch and gravel tests, and the relatively high PLC rating of the comparative tracking index indicated reduced insulation properties.

[0133] Comparative Examples 3 to 5 (which contain polyamide as the main component of the base resin and contain no polyketone or have insufficient amounts of polyketone) showed slightly reduced durability after torch and gravel tests.

[0134] Comparative Examples 6 and 7 (which contain polyketone as the main component of the base resin, but in excessive amounts) showed reduced durability after torch and gravel tests.

[0135] All embodiments containing appropriate amounts of polyketone, fiber filler, particulate filler, flame retardant and additives exhibited excellent durability after torch and gravel tests, and embodiments 2 to 4, which further contained appropriate amounts of polyamide, also exhibited excellent appearance quality.

[0136] As can be clearly seen from the foregoing, the refractory compositions and their applications according to the present invention can delay the acceleration of thermal instability and impart refractory properties when thermal instability occurs in heating devices, battery packs, etc.

[0137] Furthermore, the refractory compositions and their application products according to the present invention can have good mechanical strength, flame retardancy, insulation properties, fire resistance, injection molding processability, and appearance quality.

[0138] The effects of this invention are not limited to those described above. It should be understood that the effects of this invention include all effects that can be inferred from the description of this invention.

[0139] Although specific embodiments of the invention have been described, those skilled in the art will understand that the invention can be embodied in other specific forms without altering its technical spirit or essential characteristics. Therefore, the described embodiments should be understood as non-limiting and illustrative in all respects.

Claims

1. A refractory composition comprising: The base resin comprises 20% to 55% by weight of the total weight of the refractory composition, said base resin comprising polyketide; Fiber filler; Non-fiber fillers; and Flame retardants, wherein The length-to-diameter ratio of the fiber filler is greater than 3.

2. The fire resistant composition of claim 1, wherein, The refractory composition is used in components of the heating device.

3. The fire resistant composition of claim 1, wherein, The amount of the fiber filler is 30% to 60% by weight, based on the total weight of the composition.

4. The fire resistant composition of claim 1, wherein, The amount of the non-fibrous filler is 6% to 15% by weight, based on the total weight of the composition.

5. The refractory composition according to claim 1, wherein, The amount of the flame retardant is from 4% to 20% by weight, based on the total weight of the composition.

6. The refractory composition according to claim 1, wherein, Polyketone, according to ASTM D1238, has a melt flow rate of 150 g / 10 min to 400 g / 10 min at 240 °C and a load of 2.16 kg.

7. The refractory composition according to claim 1, wherein, The fiber filler includes at least one of glass fiber, carbon fiber, basalt fiber and quartz fiber.

8. The refractory composition according to claim 1, wherein, The non-fibrous filler includes at least one of silicon dioxide, silicone, alumina, silicon carbide, boron carbide, silicon nitride, zirconium oxide, titanium dioxide, magnesium oxide, aluminosilicate, calcium silicate, and talc.

9. The refractory composition according to claim 8, wherein, The non-fiber filler includes silica, silicone, and alumina.

10. The refractory composition according to claim 9, wherein, The total weight of the composition includes 2% to 5% silica, 2% to 5% silicone, and 2% to 5% alumina.

11. The refractory composition according to claim 1, wherein, The flame retardant includes at least one of triphenyl phosphate, trimethyl phosphate, triethyl phosphate, bisphenol diphenyl phosphate, ammonium polyphosphate, melamine phosphate, melamine pyrophosphate, melamine ammonium phosphate, melamine cyanurate, piperazine polyphosphate, xylyl diphenyl phosphate, aluminum hydroxide, and magnesium hydroxide.

12. The refractory composition according to claim 1, wherein, based on the total weight of the composition, the refractory composition further comprises 0.5% to 2% by weight of an additive, wherein, The additives include at least one of antioxidants, processing stabilizers, or activators.

13. The refractory composition according to claim 1, wherein, The base resin also contains polyamide, and the amount of polyketone is from 16% to 44% by weight and the amount of polyamide is from 4% to 11% by weight, based on the total weight of the composition.

14. A molded article, said molded article being produced by molding the refractory composition according to claim 1.

15. The molded article according to claim 14, wherein, In the following UL 2596 blowtorch and gravel tests, the surface of a specimen with a predetermined area cracks after 10 or more cycles: UL 2596 Blowtorch and Gravel Test The molded specimen was made into a sample with an area of ​​200 mm × 200 mm and a thickness of 2 mm. The specimen was then subjected to the following cycle: each cycle consisted of being exposed to a flame at 1200 °C for 15 seconds at a distance of 60 mm from the specimen surface, followed by being exposed to a flame at 1200 °C and gravel with an average diameter of 120 μm at a rate of 0.6 g / s for 5 seconds, in order to evaluate the number of cycles required for the specimen surface to crack.

16. An energy storage device, the energy storage device comprising: The outer casing is manufactured by melting and injection molding the refractory composition according to claim 1; and At least one of the battery cells or battery modules arranged in the housing.

17. A refractory composition comprising: A base resin comprising 20% ​​to 55% by weight, wherein the base resin comprises polyketone, wherein the polyketone has a melt flow rate of 150 g / 10 min to 400 g / 10 min at 240 °C and a load of 2.16 kg according to ASTM D1238. The fiber filler comprises 30% to 60% by weight, wherein the length-to-diameter ratio of the fiber filler is greater than 3; 6% to 15% by weight of non-fibrous filler; and Flame retardant in amounts of 4% to 20% by weight.

18. The refractory composition according to claim 17, further comprising one or more additives in a total amount of 0.5% to 2% by weight, wherein, The one or more additives are selected from antioxidants, processing stabilizers, and activators.

19. The refractory composition according to claim 17, wherein, The non-fibrous filler comprises silica, silicone, and alumina, each in an amount of 2% to 5% by weight of the total weight of the composition.

20. The refractory composition according to claim 17, wherein, The base resin also contains polyamide, and respectively, based on the total weight of the composition, The amount of polyketone is 16% to 40% by weight. The amount of polyamide is from 4% to 11% by weight.

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