A method for manufacturing a frame heat insulation pad

Abstract

The application discloses a manufacturing method of a frame heat insulation pad, liquid rubber is used to print a frame shape on a packaging film, then heat insulation core material is pasted and solidified to realize conversion of the liquid rubber frame into a solid rubber frame, then the packaging film is pasted, compression packaging is carried out, and finally cutting is carried out to obtain the frame heat insulation pad, the frame heat insulation pad can be manufactured in a single piece or in a plate to improve efficiency, the thinnest 0.1mm frame heat insulation pad can be manufactured, liquid rubber is directly operated on the packaging film, separate frame cloth is not needed, the frame heat insulation pad with very small frame thickness can be manufactured, the frame heat insulation pad can be manufactured in a single piece or in a plurality of plates to improve manufacturing efficiency, the manufacturing method of the traditional frame heat insulation pad is changed, the material utilization rate is higher than that of a conventional frame heat insulation pad manufacturing process, and the problem of difficulty in manufacturing an ultra-thin frame heat insulation pad is solved.

Description

Technical Field

[0001] This invention belongs to the field of heat insulation for new energy batteries, and specifically relates to a method for manufacturing a frame heat insulation pad. Background Technology

[0002] As the energy density of new energy batteries increases, the new energy vehicle and energy storage markets are placing increasingly higher demands on the thermal runaway safety of products. One common solution to avoid thermal runaway in battery packs is the use of thermal insulation pads. Among thermal insulation pads, frame-type thermal insulation pads account for a large proportion because the frame can bear the load of the battery, preventing the thermal insulation material from being squeezed and deformed by the load force, thus avoiding loss of thermal insulation performance.

[0003] However, currently, the main method for making frame heat insulation pads involves first arranging the rubber frame, heat insulation core material, and encapsulation film, and then pressing them together. The rubber frame is typically pre-calendered or die-cut from rubber material. Calendered and die-cut rubber frames not only have low rubber material utilization, but the resulting ultra-thin rubber frames are also very prone to deformation during the pre-pressing process. Die-cut rubber frames are difficult to produce for ultra-thin applications because they are easily torn and deformed during demolding, resulting in extremely low yield. Summary of the Invention

[0004] This invention provides a method for manufacturing a frame heat insulation pad, which changes the traditional preparation method of frame heat insulation pads. It avoids the difficulty of material placement and can produce ultra-thin rubber frame products, while also improving the utilization rate of rubber materials.

[0005] The technical solution adopted in this invention is as follows: A method for manufacturing a frame heat insulation pad, comprising the following steps: S1. Prepare the first encapsulation film and the second encapsulation film. The first encapsulation film and the second encapsulation film can be made of the same material or different materials, as long as they can be pressed together to achieve encapsulation.

[0006] S2, liquid rubber is used to print a liquid rubber border on the first encapsulation film; during printing, one rubber border can be printed at a time, or multiple rubber borders can be printed at a time, depending on the production needs, and the printing method is stencil printing or screen printing.

[0007] S3, set the heat insulation core material in the area defined by the liquid rubber frame, and then cure the liquid rubber frame into a solid rubber frame; or, cure the liquid rubber frame into a solid rubber frame, and then set the heat insulation core material in the area defined by the solid rubber frame.

[0008] As a preferred embodiment of the present invention, the present invention further includes the following step, S4, pasting the second encapsulation film; S5, press and seal the first encapsulation film, solid rubber frame, heat insulation core material and second encapsulation film; the press and seal can be performed in a vacuum state or a non-vacuum state.

[0009] As a preferred embodiment of the present invention, the invention further includes the following step, S6, cutting off the excess of the first encapsulation film and / or the second encapsulation film to obtain the frame heat insulation pad. The purpose of this step is to cut off excess tooling edges, improve the length and width accuracy of the frame heat insulation pad product, and remove irregular edges caused by the flow of liquid rubber. The cutting method can be die-cutting, laser cutting, hot cutting, ultrasonic cutting, etc.

[0010] As a preferred embodiment of the present invention, the thickness of the solid rubber frame is 0.1mm-10mm; and the curing temperature of the solid rubber frame does not exceed the softening and deformation temperature of the first encapsulation film; the liquid rubber is fluid before curing. For frame heat insulation pads with strict requirements on the size of the heat insulation core material, the heat insulation core material must be applied first and then cured. This avoids the slope of the inner edge of the frame caused by the rubber flowing during the curing process, which would reduce the frame thickness, and also avoids uneven shrinkage of the inner size of the rubber frame during the curing process, which would make it difficult to insert the heat insulation core material. For frame heat insulation pads with less strict requirements on the size of the heat insulation core material, the heat insulation core material can be applied first and then cured, or it can be applied first and then cured.

[0011] As a preferred embodiment of the present invention, printing is performed using steel printing or screen printing; curing is performed using room temperature curing, heat curing, or UV curing.

[0012] As a preferred embodiment of the present invention, only one liquid rubber frame is provided on the first encapsulation film, and one heat insulation pad product is produced at a time.

[0013] In a preferred embodiment of the present invention, the first encapsulation film has two or more liquid rubber frames, each of which is not adjacent to the others; or, adjacent liquid rubber frames are connected to each other. Multiple heat insulation pad products can be produced at once.

[0014] In a preferred embodiment of the present invention, the liquid rubber border can be a closed border or an open border. When it is a closed border, it is a U-shaped border; when it is an open border, it can be an open U-shaped border, a strip border, or other border shapes.

[0015] In a preferred embodiment of the present invention, when the first encapsulation film has two or more liquid rubber borders, the shapes of the liquid rubber borders on the first encapsulation film are identical, meaning that multiple products of the same shape are ultimately produced at once. The shape of the liquid rubber borders can be a closed border or an open border. When it is a closed border, it is a U-shaped border; when it is an open border, it can be an open U-shaped border, a strip border, or other border shapes. During liquid rubber printing, borders can be printed one by one, or multiple borders can be printed at once using a mold.

[0016] In a preferred embodiment of the present invention, when the first encapsulation film has two or more liquid rubber borders, the shapes of the liquid rubber borders on the first encapsulation film are not exactly the same, allowing for the production of products of different shapes at once. Borders can be printed one by one, or multiple borders can be printed at once using a mold. The liquid rubber borders can be closed or open. When closed, they are U-shaped borders; when open, they can be open U-shaped borders, strip borders, or other border shapes.

[0017] As a preferred embodiment of the present invention, the heat insulation core material is composed of any one or more of the following: aerogel composite fiber felt, nanocomposite board, aerogel composite foam, pure aerogel material, mica board, rock wool board, foam, foam, and phase change material.

[0018] In a preferred embodiment of the present invention, both the first and second encapsulation films have an adhesive layer on the side closest to the heat-insulating core material. The adhesive used in the adhesive layer is any one of epoxy adhesive, silicone adhesive, and acrylic adhesive. The adhesive layer is used to improve the adhesion to the rubber.

[0019] This invention changes the traditional method of preparing frame heat insulation pads. It uses liquid rubber to print the frame shape on the encapsulation film, and then the heat insulation core material is pasted and cured to convert the liquid rubber frame into a solid rubber frame. The liquid rubber is directly applied to the encapsulation film, eliminating the need for separate frame fabrication. This allows for the production of heat insulation pads with very thin frames. Moreover, it can be made as a single piece or in multiple pieces, improving production efficiency. Compared with conventional frame heat insulation pad manufacturing processes, it has a higher material utilization rate and solves the problem of difficult material placement for ultra-thin frames. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a flowchart illustrating the manufacturing process of the closed-mouth, square-shaped heat insulation pad of the present invention.

[0022] Figure 2 An exploded view of the closed-mouth square-shaped heat insulation pad made from the panels of this invention.

[0023] Figure 3 This is an exploded view of the single-strip frame heat insulation pad of the present invention.

[0024] Figure 4 This is an exploded view of the single-opening U-shaped frame heat insulation pad of the present invention. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] In this invention: The first encapsulation film 1-1 and the second encapsulation film 1-2 can be selected from the film material types shown in the table below, or other film material types with similar performance can be selected.

[0027] For liquid rubber, select the liquid rubbers shown in the table below or alternatives with similar properties: Example 1: A method for manufacturing a frame heat insulation pad, such as Figure 1 As shown, the following steps demonstrate the making of a U-shaped heat insulation pad: S1. Prepare the first encapsulation film 1-1 and the second encapsulation film 1-2. The first encapsulation film and the second encapsulation film can be made of the same material or different materials, as long as they can be pressed together to achieve encapsulation.

[0028] S2, a liquid rubber border 2-1 is formed by liquid rubber printing on the first encapsulation film 1-1; the printing method is stencil printing or screen printing. An adhesive is provided on the first encapsulation film 1-1, which is any one of epoxy, silicone, or acrylic adhesives, used to improve adhesion to the rubber. The liquid rubber border 2-1 is a closed U-shape, and there is only one of them.

[0029] For frame insulation products with strict requirements on the size of the insulation core material, proceed directly to step S3.

[0030] S3, heat insulation core material 3 is set in the area defined by liquid rubber frame 2-1, the heat insulation core material is pasted in place, and then the liquid rubber frame 2-1 is cured into solid rubber frame 2-2. The thickness of solid rubber frame 2-2 is 0.1mm-10mm; the thinnest is 0.1mm, the thickest is 10mm, and the thickness can also be 3mm, 5mm, 8mm, etc., designed according to actual production needs; the curing is carried out by room temperature curing, heat curing or UV curing, and the curing temperature does not exceed the temperature at which the first encapsulation film 1-1 softens and deforms.

[0031] The thermal insulation core material used is composed of one or more of the following: aerogel composite fiber felt, nanocomposite board, aerogel composite foam, pure aerogel material, mica board, rock wool board, foam (such as PE foam, EVA foam, CR foam, PU foam, natural latex foam, other rubber foam, etc.), foam (such as PE foam, PU foam, EPS / XPS foam, rubber foam, PVC foam), and phase change materials (such as crystalline hydrated salts such as Na2SO4∙10H2O, paraffin wax, fatty acids such as lauric acid, fatty alcohols such as n-octadecyl alcohol, and molten salts such as sodium carbonate and calcium fluoride).

[0032] Liquid rubber is fluid before curing. For frame insulation pads with strict requirements on the size of the insulation core material, the insulation core material must be applied first and then cured. This can avoid the slope of the inner edge of the frame caused by the flow of rubber during the curing process, which would reduce the thickness of the frame. It can also avoid uneven shrinkage of the inner size of the rubber frame during the curing process, which would make it difficult to insert the insulation core material.

[0033] S4, attach the second encapsulation film 1-2; and the second encapsulation film 1-2 has an adhesive layer, which uses an adhesive, namely, any one of epoxy adhesive, silicone adhesive, and acrylic adhesive. The adhesive is used to improve the adhesion to rubber.

[0034] S5, the first encapsulation film 1-1, the solid rubber frame 2-2, the heat insulation core material 3, and the second encapsulation film 1-2 are pressed and encapsulated; the pressing and encapsulation can be performed in a vacuum state or a non-vacuum state.

[0035] S6, cut off the excess of the first encapsulation film and / or the second encapsulation film to obtain the frame heat insulation pad 4. The cutting can be done by precision die-cutting, laser cutting, hot cutting, ultrasonic cutting, etc. In this embodiment, precision die-cutting is used. The purpose of this step is to cut off the excess tooling edge 5, improve the length and width accuracy of the frame heat insulation pad product, and remove irregular edges caused by the flow of liquid rubber.

[0036] When only one product is produced, the shape of the liquid rubber frame 2-1 can also be an open U-shape, such as... Figure 3 As shown, it can also be in the form of bars, such as... Figure 4 As shown, the production steps are the same, only the shape of the rubber frame is different.

[0037] Of course, panel production is also possible, producing multiple products at once. During printing, multiple liquid rubber borders (2-1) can be printed simultaneously. These can be printed one by one, or multiple can be printed at once using a printing mold. An example is given using multiple U-shaped border heat insulation pads. Figure 2 As shown, it can also be multiple open U-shaped frame heat insulation pads, multiple strip frame heat insulation pads, and the shape of the liquid rubber frame is determined according to the production design.

[0038] When printing multiple liquid rubber borders, they can be of the same shape or of different shapes.

[0039] Example 2: A method for manufacturing a frame heat insulation pad, specifically, a frame heat insulation pad with a U-shaped frame is provided, the preparation steps of which are as follows: S1. Prepare the first encapsulation film 1-1 and the second encapsulation film 1-2; S2. A liquid rubber frame 2-1 with a thickness of 0.1mm is formed by screen printing liquid rubber on the first encapsulation film 1-1. S3. The liquid rubber frame 2-1 is cured into a solid rubber frame 2-2. The curing temperature does not exceed the temperature at which the first encapsulation film 1-1 softens and deforms. Then, the heat insulation core material 3 is set in the area defined by the solid rubber frame 2-2. S4, attach the second sealing film 1-2; S5, press and seal the first encapsulation film 1-1, the solid rubber frame 2-2, the heat insulation core material 3, and the second encapsulation film 1-2 together; S6, cut the excess of the first encapsulation film and / or the second encapsulation film to obtain the frame heat insulation pad.

[0040] Everything else is the same as in Example 1.

[0041] In this specification, the terms "an embodiment," "example," "specific example," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0042] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for manufacturing a frame heat insulation pad, characterized in that: The steps are as follows: S1, Prepare the first encapsulation film (1-1) and the second encapsulation film (1-2). S2, liquid rubber is printed on the first encapsulation film (1-1) to form a liquid rubber border (2-1). S3, heat insulation core material (3) is provided in the area defined by the liquid rubber frame (2-1), and then the liquid rubber frame (2-1) is cured into a solid rubber frame (2-2); or, the liquid rubber frame (2-1) is cured into a solid rubber frame (2-2), and then heat insulation core material (3) is provided in the area defined by the solid rubber frame (2-2).

2. The method for manufacturing the frame heat insulation pad according to claim 1, characterized in that, It also includes the following steps: S4, attach the second sealing film (1-2); S5, the first encapsulation film (1-1), the solid rubber frame (2-2), the heat insulation core material (3) and the second encapsulation film (1-2) are pressed and encapsulated.

3. The method for manufacturing the frame heat insulation pad according to claim 2, characterized in that, It also includes the following steps: S6, cut the excess of the first encapsulation film and / or the second encapsulation film to obtain the frame heat insulation pad.

4. The method for manufacturing the frame heat insulation pad according to claim 1, characterized in that: The thickness of the solid rubber frame (2-2) is 0.1mm-10mm; The curing temperature of the solid rubber frame (2-2) does not exceed the temperature at which the first encapsulation film (1-1) softens and deforms.

5. The method for manufacturing the frame heat insulation pad according to claim 1, characterized in that: In step S2, printing is done using steel printing or screen printing; in step S3, curing is done using room temperature curing, heat curing, or UV curing.

6. The method for manufacturing the frame heat insulation pad according to claim 1, characterized in that: Only one liquid rubber frame (2-1) is provided on the first encapsulation film (1-1); Alternatively, the first encapsulation film (1-1) has two or more liquid rubber frames (2-1), each of which is not adjacent to the others; or, adjacent liquid rubber frames (2-1) are connected to each other.

7. The method for manufacturing the frame heat insulation pad according to claim 6, characterized in that: The liquid rubber frame (2-1) can be a closed frame or an open frame.

8. The method for manufacturing the frame heat insulation pad according to claim 6, characterized in that: When the first encapsulation film (1-1) has two or more liquid rubber borders (2-1), the shapes of each liquid rubber border (2-1) on the first encapsulation film (1-1) are the same; or, When the first encapsulation film (1-1) has two or more liquid rubber frames (2-1), the shapes of each liquid rubber frame (2-1) on the first encapsulation film (1-1) are not completely the same.

9. The method for manufacturing the frame heat insulation pad according to any one of claims 1-8, characterized in that: The thermal insulation core material is composed of any one or more of the following: aerogel composite fiber felt, nanocomposite board, aerogel composite foam, pure aerogel material, mica board, rock wool board, foam, foam, and phase change material.

10. The method for manufacturing the frame heat insulation pad according to any one of claims 1-8, characterized in that: An adhesive layer is provided on the side of the first encapsulation film (1-1) and the second encapsulation film (1-2) near the heat insulation core material (3). The adhesive used in the adhesive layer is any one of epoxy adhesive, silicone adhesive and acrylic adhesive.

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