Aerogel thermal insulation material

Abstract

The utility model relates to an aerogel thermal insulation material which comprises a first carrier-free film layer, an aerogel felt layer and a second carrier-free film layer which are arranged in sequence, the first carrier-free film layer and the second carrier-free film layer are carrier-free films which are formed by melting and blending thermoplastic plastics and flame retardants and then coating. According to the utility model, the carrier-free film is used as the packaging film of the aerogel thermal insulation material, a release protective film is not needed, the structure is simple, the process complexity and the cost are reduced, and the packaging film is obtained by hot melting coating of a solvent-free system, so that no solvent is discharged, and the environmental pollution is small; the carrier-free film is made of thermoplastic plastic and can be directly formed with the aerogel felt in a hot pressing mode, an adhesive layer is not needed, the influence of the adhesive layer on the performance of the heat insulation material is eliminated, and meanwhile the thermoplastic plastic is good in weather resistance and high in reliability.

Description

Technical Field

[0001] This utility model relates to the field of battery thermal insulation, and in particular to an aerogel thermal insulation material. Background Technology

[0002] In recent years, the new energy industry has developed rapidly, and the market demand for new energy vehicles has been growing. Consequently, the demand for aerogel insulation materials has also shown a continuous upward trend. In the field of new energy vehicles, aerogel insulation materials are mainly used for thermal insulation and flame retardancy between power battery cells, as well as for thermal insulation and shock absorption between modules and casings, and for external cold-proofing and high-temperature insulation layers in battery boxes. This allows for better temperature control and electronic control management of the battery, reducing the risk of battery thermal runaway.

[0003] Aerogel insulation sheets are mainly composed of ultra-thin aerogel felt and encapsulating film. Currently, the commonly used encapsulating film is mainly a single-sided coating solution of PET or PI film, which consists of a base film, an adhesive layer, and a release film. However, this encapsulating film structure has a complex process, low product yield, high cost, and its performance is easily affected by the adhesive layer. In addition, the encapsulating film has a limited shelf life. Utility Model Content

[0004] Therefore, it is necessary to provide an aerogel insulation material to address the issue that the encapsulation film structure has a significant impact on the performance of aerogel insulation sheets.

[0005] This utility model provides an aerogel thermal insulation material, comprising a first carrier-free membrane layer, an aerogel felt layer, and a second carrier-free membrane layer arranged sequentially.

[0006] The first carrier-free film layer and the second carrier-free film layer are carrier-free films formed by coating after melt blending of thermoplastic plastic and flame retardant.

[0007] In some of these embodiments, the thickness of both the first carrier-free film layer and the second carrier-free film layer is 10µm to 100µm.

[0008] In some embodiments, the thickness of the aerogel felt layer is 3 mm to 20 mm.

[0009] In some embodiments, the thermoplastic is any one or more of polyethylene, polypropylene, POE plastic and polyurethane elastomer.

[0010] In some of the embodiments, the flame retardant is any one or more of phosphorus-based flame retardants, nitrogen-based flame retardants, inorganic hydroxide flame retardants, intumescent flame retardants, and boron-based flame retardants.

[0011] In some embodiments, the interface connection between the first carrier-free membrane layer and the second carrier-free membrane layer and the aerogel felt layer is achieved by thermoforming.

[0012] Compared with the prior art, the present invention has at least the following beneficial effects:

[0013] This invention uses a carrier-free membrane as the encapsulation film for aerogel insulation material, eliminating the need for a release liner. This simplifies the structure, reduces process complexity and cost, and utilizes a solvent-free hot-melt coating system, resulting in zero solvent emissions and minimal environmental pollution. The carrier-free membrane is made of thermoplastic, allowing for direct hot-pressing with aerogel felt without an adhesive layer, thus eliminating the influence of adhesive layers on the insulation material's performance. Furthermore, thermoplastics offer excellent weather resistance and high reliability. Adding a flame retardant to the carrier-free membrane makes it flame-retardant, suitable for battery insulation applications. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the cross-sectional structure of an aerogel insulation material according to an embodiment of the present invention. Detailed Implementation

[0015] To make the above-mentioned objects, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a full understanding of this utility model. However, this utility model can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed below.

[0016] It should be noted that when an element is said to be "fixed to" another element, it can be directly on the other element or there may be an intervening element. When an element is said to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. Conversely, when an element is said to be "directly on" another element, there is no intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0017] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0018] See Figure 1 The present invention provides a schematic diagram of the cross-sectional structure of an aerogel thermal insulation material, comprising a first carrier-free membrane layer 1, an aerogel felt layer 2, and a second carrier-free membrane layer 3 arranged sequentially.

[0019] The first carrier-free film layer 1 and the second carrier-free film layer 3 are carrier-free films formed by coating after melt blending of thermoplastic plastic and flame retardant.

[0020] In this embodiment, the aerogel felt layer 2 is a flexible thermal insulation felt layer composed of nano-silica or metallic aerogel as the main material, combined with carbon fiber, ceramic glass fiber cotton, or pre-oxidized fiber felt. The first carrier-free film layer 1 and the second carrier-free film layer 3 do not require adhesive layers or release films, resulting in a simpler encapsulation film structure and a simpler processing technology, thereby reducing production costs. Simultaneously, the thermoplastic plastic and flame retardant are hot-melt coated, eliminating the need for solvents in the coating process and reducing environmental pollution.

[0021] It should be understood that aerogel felt has many pores, so it needs to be encapsulated. Traditional PET / PI coated films use PET / PI as the base film, which requires an adhesive layer to encapsulate the aerogel felt. However, this invention uses thermoplastic plastic as the main material, which can encapsulate the aerogel through hot pressing, so that the carrier-free film does not need an adhesive layer, thus eliminating the influence of the adhesive layer on the performance of the thermal insulation material.

[0022] Optionally, the interface connection between the first carrier-free membrane layer 1 and the second carrier-free membrane layer 3 and the aerogel felt layer 2 is achieved by hot pressing. The first carrier-free membrane layer 1 and the second carrier-free membrane layer 3 are made of thermoplastic plastic, which softens and bonds with the aerogel felt during hot pressing, and hardens again after cooling, thereby achieving the bonding between the first carrier-free membrane layer 1 and the second carrier-free membrane layer 3 and the aerogel felt.

[0023] In some embodiments, the thickness of the first carrier-free membrane layer 1 and the thickness of the second carrier-free membrane layer 3 are both 10µm to 100µm. The thickness of the first carrier-free membrane layer 1 and the thickness of the second carrier-free membrane layer 3 can be the same or different, but are preferably the same. This embodiment uses a carrier-free membrane with a thickness of 10µm to 100µm to meet the application requirements of aerogel insulation in different sizes and insulation scenarios, while also making the carrier-free membrane less prone to bending and damage during use, and avoiding cost waste due to excessive material usage.

[0024] In some embodiments, the thickness of the aerogel felt layer 2 is 3mm to 20mm. This embodiment can meet the aerogel insulation strength requirements of different insulation scenarios, wherein the thicker the aerogel felt layer, the better the insulation effect.

[0025] In some embodiments, the thermoplastic is any one or more of polyethylene, polypropylene, POE plastic, and polyurethane elastomer. Polyethylene has heat resistance and a softening point of 120°C to 125°C, meeting the requirements of most battery insulation scenarios, while also possessing excellent insulation properties to meet battery insulation requirements. Polypropylene also has good heat resistance and excellent insulation properties, effectively protecting electronic components from electromagnetic interference and leakage problems. POE plastic is a thermoplastic elastomer polymerized in situ using metallocene catalysts to polymerize ethylene and octene, and it has excellent insulation and mechanical properties.

[0026] In some embodiments, the flame retardant is any one or more of phosphorus-based flame retardants, nitrogen-based flame retardants, inorganic hydroxide flame retardants, intumescent flame retardants, and boron-based flame retardants. In this embodiment, the addition of a flame retardant effectively retards the flame during battery insulation, preventing the insulation material from igniting due to battery heating and improving battery insulation safety.

[0027] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0028] The embodiments described above are merely illustrative of several implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. Aerogel thermal insulation material, characterized in that, The first carrier-free film layer, the aerogel felt layer and the second carrier-free film layer are sequentially arranged. The first carrier-free film layer and the second carrier-free film layer are carrier-free films formed by coating after melt blending of thermoplastic and flame retardant; the first carrier-free film layer and the second carrier-free film layer do not need adhesive layer and release protective film; the interface connection between the first carrier-free film layer, the second carrier-free film layer and the aerogel felt layer adopts hot press forming.

2. The aerogel thermal insulation material of claim 1, wherein, The thickness of the first carrier-free film layer and the thickness of the second carrier-free film layer are both 10um-100um.

3. The aerogel thermal insulation material of claim 1, wherein, The thickness of the aerogel felt layer is 3mm-20mm.

4. The aerogel thermal insulation material of claim 1, wherein, The thermoplastic is any one of polyethylene, polypropylene, POE plastic and polyurethane elastomer.

5. The aerogel thermal insulation material of claim 1, wherein, The flame retardant is any one of phosphorus-based flame retardant, nitrogen-based flame retardant, inorganic hydroxide flame retardant, intumescent flame retardant and boron-based flame retardant.

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