Thermal insulation element, battery pack and vehicle

Abstract

A thermal insulation element, characterized in that it comprises: a heat-insulating core material, the heat-insulating core material comprising a bottom surface and a surface arranged opposite each other, two opposite side surfaces, and two opposite end surfaces connected between the bottom surface and the surface; and a film material wrapped around the outside of the heat-insulating core material to encapsulate the heat-insulating core material, wherein the film material is folded from the bottom surface along both side surfaces to the surface and at least partially overlapped on the surface to form a first overlap portion. Among them, the film material also forms a second overlap portion on each of the two end surfaces, and the second overlap portion includes a first overlap layer, a second overlap layer, and a third overlap layer stacked one after the other; the first overlap layer is folded from the side surface to the heat-insulating core material; the second overlap layer is folded from the surface to the end surface and at least partially covers the first overlap layer; the third overlap layer is folded from the bottom surface to the end surface and at least partially covers the second overlap layer; the film material further forms a first lamination portion extending from the third overlap layer to the surface and abutting against the film material on the surface.

Description

Technical area

[0001] The present application relates to a heat insulation member, a battery pack using the heat insulation member, and a vehicle using the battery pack. Background technology

[0002] The thermal insulation elements used in batteries for new energy vehicles are usually made of thermal insulation core materials such as aerogel felt and fiber felt. However, the thermal insulation core materials (especially aerogel felt) are fragile and must be encapsulated before use to prevent powder loss. A common encapsulation method is to sandwich the thermal insulation core material between two pieces of film material and bond the two pieces of film material together at their edges by hot pressing and adhesive to encapsulate the aerogel felt. However, in this encapsulation method, the film material forms a sealed edge around the aerogel felt, reducing the aerogel felt content and creating a thermal bridge at the seam edge, which impairs the thermal insulation effect. Contents of the utility model

[0003] The first aspect of the present application provides a thermal insulation element comprising: a heat-insulating core material, the heat-insulating core material comprising a bottom surface and a surface arranged opposite each other, two opposite side surfaces, and two opposite end surfaces connected between the bottom surface and the surface; and a film material wrapped around the outside of the heat-insulating core material to encapsulate the heat-insulating core material, wherein the film material is folded from the bottom surface along both side surfaces to the surface and at least partially overlapped on the surface to form a first overlap portion.

[0004] Among them, the film material also forms a second overlap portion on each of the two end surfaces, and the second overlap portion includes a first overlap layer, a second overlap layer, and a third overlap layer stacked one after the other; the first overlap layer is folded from the side surface to the heat-insulating core material; the second overlap layer is folded from the surface to the end surface and at least partially covers the first overlap layer; the third overlap layer is folded from the bottom surface to the end surface and at least partially covers the second overlap layer; the film material further forms a first lamination portion extending from the third overlap layer to the surface and abutting against the film material on the surface.

[0005] The heat insulation member provided in the embodiment of the present application forms a first overlap portion on the surface of the heat-insulating core material and a second overlap portion on the two end surfaces of the heat-insulating core material by disposing a film material. The second overlap portion is bonded to the film material on the surface via a first adhesive portion bonded to the third overlap layer, so that the film material can encapsulate the heat-insulating core material along the outer contour of the heat-insulating core material. Subsequently, the edge seal of the heat insulation member is bonded to the outer contour of the heat-insulating core material, thereby increasing the proportion of the heat-insulating core material in the heat insulation member, which has a positive effect on improving the thermal insulation effect.

[0006] In one embodiment, the film material comprises a base material layer and an adhesive layer, wherein the adhesive layer is arranged on one side of the base material layer and is designed to connect a part of the film material to a part of the heat-insulating core material and to bond parts of the film materials together.

[0007] In one embodiment, the film material further comprises a second lamination portion formed between the second overlap layer and the third overlap layer, wherein the second lamination portion is formed by extending from the second overlap layer and being bonded to the third overlap layer.

[0008] In one embodiment, a length of the second lamination portion in a direction away from the second overlap layer is greater than 3 mm.

[0009] In one embodiment, the length of the first lamination section in a direction away from the third overlap layer is greater than 3 mm.

[0010] In one embodiment, the first overlap portion comprises an overlap region and a reinforcement region, and a width of the reinforcement region is greater than a width of the overlap region.

[0011] In one embodiment, the film material, in the unfolded state, is defined by a bottom surface attachment region, a side surface attachment region, a surface attachment region, a first overlap region, a second overlap region, a third overlap region, a first lamination region, and a second lamination region; the side surface attachment regions are arranged on both sides of the bottom surface attachment region along the first direction, and the surface attachment region is arranged on a side of the side surface attachment region facing away from the bottom surface attachment region; the third overlap section is arranged on both sides of the bottom surface attachment region along the second direction; the first lamination region is arranged on a side of the third overlap section facing away from the bottom surface attachment region;the first overlap portion is arranged on both sides of the side attachment region along the second direction; the second overlap portion is arranged on both sides of the surface attachment region along the second direction; the second lamination region, in the unfolded state, is located at the four corners of the film material and adjacent to the second overlap portion. In one embodiment, first notches are opened at the four corners of the film material, and the film material is defined with a first edge and a second edge at the position of each of the first notches; the first edge is parallel to the first direction and is located at least on a side of the second lamination region facing away from the second overlap portion; the second edge is parallel to the second direction and does not overlap with the bottom surface attachment region, at least in the first direction.

[0012] In one embodiment, first notches are opened at the four corners of the film material, and the film material is defined at the position of each of the first notches with a first edge and a second edge; the first edge is parallel to the first direction and is located at least on a side of the second lamination area facing away from the second overlap area; the end point at which the second edge is connected to the first edge is located in the third overlap area, and the second edge extends in the first direction in a direction away from the first edge, and the angle between the second edge and the second direction is 22.5° to 32.5°.

[0013] In one embodiment, second notches are opened at the four corners of the film material, the second notches being configured to form an exposed area exposing the surface after the film material is folded onto the surface, the exposed area being covered by the first laminating portion.

[0014] In one embodiment, the thermally insulating core material comprises one or more overlays of a fiber material layer, a fiber-reinforced aerogel composite material layer, a phase change material layer, a strain material layer, and an elastic layer.

[0015] In one embodiment, the fiber material layer is selected from one or more of glass fiber mats, pre-oxidized silk fiber mats, and ceramic fiber mats.

[0016] In one embodiment, the fiber-reinforced aerogel composite material layer is selected from one or more of the following materials: glass fiber reinforced aerogel felt, pre-oxidized silk fiber reinforced aerogel felt, and ceramic fiber reinforced aerogel felt.

[0017] A second aspect of the present application provides an encapsulation method for encapsulating a heat-insulating core material to form a heat-insulating member as described in the above embodiment, comprising: Folding the film material, which initially has a flat shape, from the bottom surface of the heat-insulating core material to the surface along the two side surfaces; Folding the part of the film material coplanar with the side surface to the end surface; Folding the part of the film material coplanar with the surface to the end face; Folding the part of the film material coplanar with the bottom surface to the end surface; Folding the part of the film material coplanar with the end face to the surface; Evacuating the film material and the heat-insulating core material and hot-pressing and bonding the film material.

[0018] In one embodiment, the film material further forms a second lamination portion between the second overlap layer and the third overlap layer, and after the step of folding the portion of the film material coplanar with the surface to the end face, further comprises: bonding the second lamination portion to the corresponding portion of the film material.

[0019] A third aspect of the present application provides a battery pack comprising: several battery cells; and the above-mentioned thermal insulation element, wherein one or more of the thermal insulation elements are arranged between two adjacent battery cells; and / or they are arranged on a side of the battery cell facing away from another battery cell.

[0020] A fourth aspect of the present application provides a vehicle comprising: a drive device; and the battery pack mentioned above, whereby the battery pack is designed to supply power to the drive device. Figures Fig. 1 is a schematic diagram of the structure of a heat insulation member in an embodiment of the present application. Fig. Figure 2 is a schematic cross-sectional view of the structure of Fig. 1. Fig. 3 is a schematic diagram showing the structure of a heat insulating member in another embodiment of the present application. Fig. 4 is a partially expanded schematic representation of Fig. 1. Fig. 5 is a schematic illustration of a partially unfolded state of a film material in an embodiment of the present application. Fig. 6 is a schematic representation of the unfolded state of the film material in another embodiment of the present application. Fig. Fig. 7 is a schematic representation of a partially unfolded state of a heat insulation element, which corresponds to the film material in Fig. 6 corresponds. Fig. 8 is a schematic representation of the unfolded state of a film material in another embodiment of the present application. Fig. 9 is a schematic representation of the unfolded state of a film material in another embodiment of the present application. Fig. 10 is a schematic representation of a partially unfolded state of a film material in Fig. 9. Fig. 11 is a schematic representation of the encapsulation state of the film material in Fig. 9 . Fig. 12 is a flowchart of an encapsulation method in one embodiment of the present application. Fig. 13 is a schematic representation of the structure after step S1 in Fig. 12. Fig. 14 is a schematic representation of the structure after step S2 in Fig. 12 . Fig. 15 is a schematic diagram of the structure of a battery pack in an embodiment of the present application. Fig. 16 is a schematic diagram of the structure of a vehicle in an embodiment of the present application. Reference symbols of the main components: 100 thermal insulation elements 10 Heat-insulating core material 11 Bottom surface 13 Surface 15 side surface 17 Frontal surface 30 foil material 31 First overlap section 311 Overlap area 313 Strengthening area 33 Second overlap section 35 First laminating section 331 First overlap layer 333 Second overlap layer 335 Second lamination section 337 Third overlap layer 37 Base material layer 39 Adhesive layer 41 Subsurface fastening area 42 Side surface fastening area 43 Surface mounting area 44 First overlap area 45 Second overlap area 451 First main body section 453 First folding section 46 Third overlap area 461 Second main body section 463 Second folding section 47 First laminating area 48 Second laminating area 50 First notch 51 First page 53 Second page 60 Second notch 70 Exposed area W First Length H Second length P Endpoint α angle 200 battery pack 210 battery cells 300 vehicles 310 drive device X First Direction Y Second direction S1, S2, S3, S4, S5, S6 step Specific embodiments

[0021] The technical solutions in the embodiments of the present application are described clearly and completely below in conjunction with the figures in the embodiments of the present application. Obviously, the described embodiments represent only a portion of the embodiments of the present application and not all embodiments.

[0022] 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 application belongs. The terms used in the description of this application are for the purpose of describing specific embodiments only and are not intended to limit this application.

[0023] In order to further explain the technical means and effects used in the present application to achieve the intended purpose, the present application will be described in detail below together with the accompanying drawings and preferred embodiments.

[0024] Please see Fig. 1 and Fig. 2 together. The thermal insulation member 100 provided in the embodiment of the present application includes a thermally insulating core material 10 and a film material 30. The thermally insulating core material 10 has a substantially rectangular parallelepiped structure and includes a bottom surface 11 and a surface 13 arranged opposite each other, two opposite side surfaces 15 connecting the bottom surface 11 and the surface 13, and two opposite end surfaces 17. The film material 30 is wrapped around the outside of the thermally insulating core material 10 to encapsulate the thermally insulating core material 10.

[0025] In this embodiment, the heat-insulating core material 10 is a single layer of aerogel felt or a superposition of multiple layers of aerogel felt. The aerogel felt is based on a fiber felt body made of, for example, glass fiber or ceramic fiber. The prepared sol is bonded to the fiber felt body by impregnation or spraying, a gel felt is formed by the sol-gel reaction in the base material, the gel felt body is then chemically modified, and finally, the gel felt body is produced by a supercritical or normal pressure drying process. Aerogel felt is a good heat-insulating material and can be used as a heat-insulating element in batteries of new energy vehicles. However, aerogel is fragile and therefore prone to powder loss. Therefore, it must be encapsulated with a film material 30.

[0026] In other embodiments, the thermally insulating core material 10 may also be one or more superpositions of a fibrous material layer, a fiber-reinforced aerogel composite material layer, a phase-change material layer, a strain material layer, and an elastic layer. Multi-layer overlap structures may be stacked directly on top of one another or bonded together by adhesives. The present application does not impose any restrictions in this regard. The fibrous material layer is selected from one or more of the following materials: glass fiber felt, pre-oxidized silk fiber felt, and ceramic fiber felt. The fiber-reinforced aerogel composite material layer is selected from one or more of the following materials: glass fiber reinforced aerogel felt, pre-oxidized silk fiber reinforced aerogel felt, and ceramic fiber reinforced aerogel felt.The elastic layer may be made of various types of foam, such as polyethylene foam, melamine foam, polyurethane foam, etc. The heat-insulating core material 10 made of the above-mentioned material also has the problem that it is fragile and powdery and therefore also needs to be encapsulated with the film material 30.

[0027] In this embodiment, the heat-insulating core material 10 is a rectangular parallelepiped, and the heat-insulating core material 10 has a length of 253.5 mm, a width of 103.5 mm, and a thickness of 4.0 to 4.5 mm. The length of the heat-insulating core material 10 refers to the length of the edge connecting the bottom surface 11 and the side surface 15, the width of the heat-insulating core material 10 refers to the length of the edge connecting the bottom surface 11 and the end surface 17, and the thickness of the heat-insulating core material 10 refers to the length of the edge connecting the end surface 17 and the side surface 15. In other embodiments, the size of the heat-insulating core material 10 may also be set according to the specific usage requirements, and the shape of the heat-insulating core material 10 may also be set to other hexahedrons, which is not limited in the present application.

[0028] The film material 30 comprises a base material layer 37 and an adhesive layer 39, wherein the base material layer 37 consists of polyethylene glycol terephthalate (PET) and the adhesive layer 39 consists of a thermosetting adhesive. The adhesive layer 39 is arranged on one side of the base material layer 37 and is designed to bond a portion of the film material 30 to a portion of the heat-insulating core material 10 and to bond portions of the film materials 30 to one another.

[0029] In this embodiment, the thickness of the film material 30 is 0.05±0.005 mm, the thickness of the base material layer 37 is 0.025±0.002 mm, and the thickness of the adhesive layer 39 is 0.025±0.002 mm. In other embodiments, the thickness of the film material 30 can also be adjusted according to specific application requirements, and the present application imposes no limitation in this regard.

[0030] More specifically, the sheet material 30 is folded from the bottom surface 11 of the heat-insulating core material 10 along the two side surfaces 15 to the surface 13 and at least partially overlaps the surface 13 to form a first overlap portion 31. The sheet material 30 further has second overlap portions 33 formed respectively on the two end surfaces 17, wherein the second overlap portion 33 includes a first overlap layer 331, a second overlap layer 333, and a third overlap layer 337 stacked sequentially. The first overlap layer 331 is folded from the side surface 15 to the end surface 17 of the heat-insulating core material 10. The second overlap layer 333 is folded from the surface 13 to the end face 17 of the heat-insulating core material 10 and at least partially covers the first overlap layer 331.The third overlap layer 337 is folded from the bottom surface 11 to the end surface 17 of the heat-insulating core material 10 and at least partially covers the first overlap layer 331 and the second overlap layer 333. The film material 30 further forms a first lamination section 35 which extends from the third overlap layer 337 to the surface 13 and is connected to a part of the film material 30 located on the surface 13.

[0031] In this case, a part of the film material 30 is bonded to the surface of the heat-insulating core material 10 so that the adhesive layer 39 is designed to bond the base material layer 37 and the heat-insulating core material 10, the other part of the film material 30 overlaps, and the adhesive layer 39 is designed to bond the overlapping part of the base material layer 37 to achieve the encapsulation structure.

[0032] The heat insulation member 100 provided in the embodiment of the present application forms a first overlap portion 31 on the surface 13 of the heat insulating core material 10 and a second overlap portion 33 on the two end surfaces 17 of the heat insulating core material 10 by arranging a film material 30.The second overlap portion 33 is bonded to the film material 30 on the surface 13 via a first adhesive portion bonded to the third overlap layer 337, so that the film material 30 can encapsulate the heat-insulating core material 10 along the outer contour of the heat-insulating core material 10, and then the edge seal of the heat-insulating element 100 is applied to the outer contour of the heat-insulating core material 10, thereby increasing the proportion of the heat-insulating core material 10 in the heat-insulating element 100, which has a positive effect on the heat-insulating effect.

[0033] In this embodiment, the width of the first overlap portion 31 is greater than or equal to 5 mm. Specifically, the first overlap portion 31 is the overlap area of ​​the part of the sheet material 30 that is folded over from the two side surfaces 15 and extends to the surface 13. The sheet materials 30 are bonded together at the position of the first overlap portion 31, thereby fixing the sheet material 30 and further encapsulating the heat-insulating core material 10.

[0034] With reference to Fig. 3, in another embodiment, the first overlap portion 31 comprises an overlap region 311 and a reinforcement region 313, wherein the width of the reinforcement region 313 is greater than the width of the overlap region 311. In particular, the overlap width of the part of the film material 30 corresponding to the reinforcement region 313 is greater than the overlap width of the part of the film material 30 corresponding to the overlap region 311, and the reinforcement region 313 is designed to further enhance the bonding strength of the film material 30 and thereby increase the structural strength of the thermal insulation element 100. The width of the reinforcement region 313 can be one to two times that of the overlap region 311.For example, if the width of the overlap portion 311 is 5 mm, the width of the reinforcement portion 313 may be 10 mm, or if the width of the overlap portion 311 is 3 mm, the width of the reinforcement portion 313 may be 5 mm. There may be one reinforcement portion 313 or two or more reinforcement portions 313, and the present application imposes no limitation in this regard.

[0035] In this embodiment, the length of the first lamination portion 35 in the direction away from the third overlap layer 337 is greater than 3 mm. Specifically, the first lamination portion 35 is bonded to the third overlap portion and bonded to the surface 13 to fix the relative positions of the first overlap layer 331, the second overlap layer 333, and the third overlap layer 337, so that the first overlap layer 331, the second overlap layer 333, and the third overlap layer 337 are sequentially stacked on the end face 17.By setting the length of the first lamination portion 35 extending from the third overlap layer 337 to the surface 13 to more than 3 mm, the first lamination portion 35 can be more stably bonded to the surface 13, thereby ensuring that the stress generated by the superposition of the first overlap layer 331, the second overlap layer 333, and the third overlap layer 337 does not easily cause the first lamination portion 35 to fall off the surface 13, which is beneficial to improving the structural strength of the heat insulation member 100.

[0036] With reference to Fig. 4, in the present embodiment, the film material 30 further comprises a second lamination portion 335, wherein the second lamination portion 335 is formed between the second overlap layer 333 and the third overlap layer 337 and laminated to the third overlap layer 337. Specifically, the second lamination portion 335 is formed by extending the second overlap layer 333 and bonded to the third overlap layer 337 to determine the relative position between the second overlap layer 333 and the third overlap layer 337.

[0037] In this embodiment, the length of the second lamination portion 335 in the direction away from the second overlap layer 333 is greater than 3 mm. Specifically, the second lamination portion 335 extends from the second overlap layer 333 and is bonded to the third overlap region 46, thereby fixing the second overlap layer 333 at the position of the bonding end face 17. When the length of the second lamination portion 335 in the direction away from the second overlap layer 333 is greater than 3 mm, it can be bonded more firmly to the third overlap region 46, thereby preventing the second lamination portion 335 from falling off due to the stress generated by folding the second overlap layer 333.

[0038] With reference to Fig. 5. In this embodiment, the film material 30 is approximately rectangular in its fully deployed state. The film material 30, in its unfolded state, is defined by a bottom surface attachment region 41, a side surface attachment region 42, a surface attachment region 43, a first overlap region 44, a second overlap region 45, a third overlap region 46, a first lamination region 47, and a second lamination region 48; the side surface attachment regions 42 are arranged on both sides of the bottom surface attachment region 41 along the first direction X, and the surface attachment region 43 is arranged on a side of the side surface attachment region 42 facing away from the bottom surface attachment region 41; the third overlap portion 46 is arranged on both sides of the bottom surface attachment region 41 along the second direction Y.the first lamination region 47 is arranged on the side of the third overlap region 46 facing away from the bottom surface attachment region 41; the first overlap region 44 is arranged on both sides of the side attachment region 42 along the second direction Y; the second overlap region 45 is arranged on both sides of the surface attachment region 43 along the second direction Y; the second lamination region 48 is located at the four corners of the film material 30 in the unfolded state and adjoins the second overlap region 45.

[0039] The bottom surface fastening region 41 is arranged corresponding to the bottom surface 11 of the heat-insulating core material 10 and is designed for fastening to the bottom surface 11. The side surface fastening region 42 is arranged corresponding to the side surface 15 of the heat-insulating core material 10 and is designed for fastening to the side surface 15. The surface fastening region 43 is arranged corresponding to the surface 13 of the heat-insulating core material 10 and is designed for fastening to the surface 13.

[0040] Please see Fig. 4 and Fig. 5 together. The first overlap region 44 is configured to form the first overlap layer 331, the second overlap region 45 is configured to form the second overlap layer 333, the second lamination region 48 is configured to form the second lamination section 335, the third overlap region 46 is configured to form the third overlap layer 337, and the first lamination region 47 is configured to form the first lamination section 35.

[0041] Please see the Fig. 6 and Fig. 7 together. In a further embodiment, in the unfolded state, first notches 50 are opened at the four corners of the film material 30, wherein the film material 30 forms a first edge 51 and a second edge 53 at the position of the first notch 50, and the first edge 51 runs parallel to the first direction X and is located on the second lamination area 48. That is, compared to the Fig. 5, the film material 30 in this embodiment cuts off a corner portion of the second lamination region 48, thereby reducing the area of ​​the second lamination region 48. In this embodiment, the length of the second lamination portion 335 in the direction away from the second overlap layer 333 is not limited, and the second lamination portion 335 is designed only to overlap with the third overlap layer 337 to ensure that the film material 30 has a sealed structure at the end face 17.By reducing the area of ​​the second lamination region 48, the area of ​​the second lamination portion 335 after encapsulation can be reduced, thereby reducing the thickness of the second overlap portion 33, which helps to avoid the overlap of multiple layers of film materials 30 and thus forming sharp corners with high hardness that could be damaged by collisions during transportation of the thermal insulation member 100.

[0042] The second edge 53 is connected to the first edge 51, runs parallel to the second direction Y, and does not overlap with the undersurface attachment region 11 at least in the first direction X. In particular, the second edge 53 can be opened at any location between the second lamination region 48 and the first overlap region 44, so that the thickness of the sheet material 30 is reduced after opening the first notch 50 after folding to form the second overlap portion 33, which helps to avoid the overlap of multiple layers of sheet materials 30 to form sharp corners with high hardness, which in turn would lead to damage to the sharp corners due to collisions during transportation of the thermal insulation member 100.

[0043] With reference to Fig. 8. In a further embodiment, first notches 50 are opened at the four corners of the film material 30 in the unfolded state, and the film material 30 forms a first edge 51 and a second edge 53 at the position of the first notch 50, wherein the first edge 51 runs parallel to the first direction X and is located on the second lamination area 48. The end point P, at which the second edge 53 is connected to the first edge 51, is located in the third overlap area 46 and extends in the first direction X in a direction away from the first edge 51, and the angle α between the second edge 53 and the second direction Y is 22.5° to 32.5°. In particular, based on the Fig. 9, the area of ​​the first notch 50 can be further increased by setting the second edge 53 to form an angle α with the second direction Y, and by setting the end point P at which the first edge 51 and the second edge 53 are connected to be located in the third overlap region 46, the length of the third overlap region 46 in the first direction X after opening the first notch 50 can be smaller than the width of the heat-insulating core material 10, so that the third overlap layer 337 does not cover the sharp corner position of the end surface 17, thereby reducing the thickness of the sharp corner, which contributes to avoiding the overlap of the multi-layer sheet material 30 to form a sharp corner with high hardness.

[0044] The angle α between the second edge 53 and the second direction Y can be adjusted according to specific usage requirements. In this embodiment, when the second edge 53 is opened, the magnitude of the angle α changes, thereby shifting the position of the intersection point of the second edge 53 and the first lamination region 47 away from the subsurface attachment region 11, and the position of the end point P connecting the second edge 53 and the first edge 51 in the first direction X remains unchanged. If the angle α is too large, the distance between the third overlap layer 337 formed after encapsulation and the edge of the end surface 17 is relatively large, which may impair the closed encapsulation effect.If the angle α is too small, the distance between the third overlap layer 337 after encapsulation and the edge of the end face 17 is small, so that the third overlap layer 337 formed after encapsulation is close to the sharp corner of the end face 17 and the effect of reducing the hardness of the sharp corner is poor.

[0045] The heat insulation member 100 provided in the embodiment of the present application can reduce the thickness of the second overlap portion 33 formed by the sheet material 30 folded and encapsulated on the heat insulation core material 10 by removing the edges and corners of the sheet material 30 in the unfolded state. While ensuring that the heat insulation core material 10 is sealed and encapsulated, the thickness of the sharp corners formed by the sheet material 30 covering the end surface 17 of the heat insulation core material 10 can also be reduced, thereby preventing the overlap of multiple layers of the sheet material 30 to form sharp corners with high hardness, which contributes to preventing air leakage due to damage to the sheet material 30 at the position of the sharp corners during use or transportation of the heat insulation member 100.

[0046] Please see the Fig. 9, Fig. 10 and Fig. 11 together. In a further embodiment, second notches 60 are opened at the four corners of the film material 30 in the unfolded state. The second notches 60 are designed to form an exposed area 70 that exposes the surface 13 after the film material 30 has been folded onto the surface 13, and the exposed area 70 is covered by the first laminating section 35. In particular, the second notch 60 is formed at least on the surface attachment area 43 so that after the film material 30 has been folded onto the surface 13, an exposed area 70 can be formed to expose the heat-insulating core material 10. The exposed area 70 can be covered by the first laminating section 35, i.e.the first length W of the exposed region 70 in the first direction X is less than the length of the first lamination section 35 in the first direction X, and the second length H of the exposed region 70 in the second direction Y is less than the length of the first lamination section 35 in the second direction Y. For example, the first length W may be any length in a range of 2 mm to 5 mm, such as 2 mm, 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, or 5 mm. The second length H may be any length in a range of 1 mm to 2 mm, for example, 1 mm, 1.2 mm, 1.4 mm, 1.6 mm, 1.8 mm, or 2 mm. The present application does not impose any limitation in this regard.

[0047] The second notch 60 can be opened alone on the film material 30 or together with the first notch 50 on the film material 30, without any restriction being provided in this regard in the present application.

[0048] By providing the second notch 60, the exposed portion 70 formed by the second notch 60 can expose a portion of the heat-insulating core material 10, thereby preventing the heat-insulating core material 10 from being completely sealed after the film material 30 encapsulates the heat-insulating core material 10. This contributes to preventing the film material 30 from bursting due to internal gas and further increasing the service life of the heat-insulating member 100. At the same time, by arranging the exposed portion 70 to be covered by the first lamination portion 35, powder loss can be prevented, ensuring air permeability while maintaining the encapsulation effect.

[0049] With reference to Fig. 12, the embodiment of the present application further provides an encapsulation method for a thermal insulation member 100, comprising: Step S1: Folding the film material 30 from the bottom surface 11 of the heat-insulating core material 10 along the two side surfaces 15 to the surface 13; Step S2: Folding the part of the film material 30 coplanar with the side surface 15 to the end surface 17; Step S3: Folding the part of the film material 30 coplanar with the surface 13 to the end face 17; Step S4: Folding the part of the film material 30 coplanar with the bottom surface 11 to the end surface 17; Step S5: Folding the part of the film material 30 coplanar with the end face 17 to the surface 13; Step S6: Evacuating the film material 30 and the heat-insulating core material 10 and hot-pressing and bonding the film material 30.

[0050] The structure of the thermal insulation element 100 according to the embodiment of the present application will be described in more detail below in combination with the above-mentioned encapsulation method.

[0051] With reference to Fig. 13, in step S1, the film material 30 is folded from the bottom surface 11 along the contours of the side surface 15 and the surface 13 of the heat-insulating core material 10 to form a cylindrical structure, thereby internally enveloping the heat-insulating core material 10. The two surface attachment regions 43 partially overlap and form a first overlap section 31.

[0052] After step S1, the method further comprises performing heat setting on the first overlap portion 31 so that the overlap portions of the film material 30 are attached to each other, thereby fixing the structure of the film material 30 formed after step S1.

[0053] With reference to Fig. 5 and Fig. 14, in step S2, the first overlap region 44, in which the film material 30 and the side surface 15 are coplanar, is folded along the contour of the heat-insulating core material 10 in the direction of the end surface 17, thereby forming a first overlap layer 331.

[0054] The second overlap portion 45 includes a first main body portion 451 and a first folding portion 453, and the first folding portion 453 is located between the first overlap portion 44 and the first main body portion 451, such that when the first overlap portion 44 is folded toward the end face 17, the first folding portion 453 is driven by the first overlap portion 44 to fold with the first main body portion 451 and form an angular structure.The third overlap portion 46 includes a second main body portion 461 and a second folding portion 463, and the second folding portion 463 is located between the second main body portion 461 and the first overlap portion 44, such that when the first overlap portion 44 is folded toward the end face 17, the second overlap portion 463 is driven by the first overlap portion 44 to fold with the second main body portion 461 and form an angular structure.

[0055] After step S2, the method further includes hot-pressing and bonding the overlapping surface of the first folded portion 453 and the first main body portion 451 to join the first folded portion 453 and the first main body portion 451 together. And, the overlapping portion of the second folded portion 463 and the second main body portion 461 is hot-pressed and bonded to fasten the second folded portion 463 and the second main body portion 461 together. Subsequently, the structure of the sheet material 30 formed after step S2 is fixed.

[0056] Please see Fig. 4 and Fig. 8 together. In step S3, the second overlap region 45, in which the film material 30 and the surface 13 are coplanar, is folded along the contour of the heat-insulating core material 10 in the direction of the end face 17, thereby forming a second overlap layer 333. The length of the second overlap region 45 in the second direction Y corresponds to the thickness of the heat-insulating core material 10, so that the second overlap layer 333 extends straight from the side of the end face 17 near the surface 13 to the side of the end face 17 near the bottom surface 11.

[0057] The second lamination region 48 overlaps with the third overlap region 46 when the second overlap region 45 is folded. After step S3, the second lamination region 48 is further laminated to the third overlap region 46, where the film material 30 is coplanar with the bottom surface 11, to form a second lamination section 335.

[0058] Specifically, step S4 and step S5 comprise first folding the third overlap region 46 along the contour of the end face 17 of the heat-insulating core material 10 such that the third overlap region 46 covers the end face 17 to form a third overlap portion, and then folding the first lamination region 47 connected to the third overlap region 46 along the contour of the surface 13 of the heat-insulating core material 10, thereby forming a first lamination portion 35 for connecting to a part of the film material 30 on the surface 13.

[0059] In step S6, the film material 30 and the heat-insulating core material 10 are first vacuum-sealed and then hot-pressed and bonded to the film material 30, so that the film material 30 and the heat-insulating core material 10 are firmly seated in the encapsulated heat-insulating element 100. This prevents the heat-insulating element 100 from leaking and breaking when subjected to external pressure due to residual gas remaining inside.

[0060] The encapsulation method provided in the embodiment of the present application folds and adjusts the film material 30 sequentially along the outer contour of the heat-insulating core material 10, so that the edge seal of the final heat-insulating element 100 is adapted to the outer contour of the heat-insulating core material 10, thereby increasing the proportion of the heat-insulating core material 10 in the heat-insulating element 100, which has a positive effect on improving the heat insulation effect.The thermal insulation member 100 provided in the embodiment of the present application can further reduce the thickness of the second overlap portion 33 by providing the first notches 50 at the four corners of the sheet material 30, thereby preventing the sheet material 30 from becoming too hard at the end surface 17 due to too many layers, thus preventing damage and leakage due to excessive hardness, which has a positive effect on the structural strength of the thermal insulation member 100.

[0061] With reference to Fig. 15, the embodiment of the present application also provides a battery pack 200, which in the above embodiment comprises a plurality of battery cells 210 and at least one thermal insulation element 100, wherein at least one thermal insulation element 100 is arranged between two adjacent battery cells 210 and / or on a side of the battery cell 210 facing away from another battery cell 210 in order to insulate the battery cell 210. In particular, one thermal insulation element 100 can be arranged between two adjacent battery cells 210 or a plurality of thermal insulation elements 100 can be arranged, and one or more thermal insulation elements 100 can also be arranged simultaneously on the outer side of a plurality of stacked thermal insulation elements 100, i.e., the thermal insulation element 100 can be arranged between the battery cell 210 and the outer casing (not shown) of the battery pack 200.

[0062] The battery pack 200 provided in the embodiment of the present application is provided with the thermal insulation member 100 in the above embodiment. Since the foil material 30 of the thermal insulation member 100 is encapsulated and arranged along the contour of the thermal insulation core material 10, the contact area between the battery cell 210 and the thermal insulation member 100 substantially corresponds to the surface 13 and the bottom surface 11 of the thermal insulation core material 10 (the thickness of the foil material 30 can be neglected), thereby improving the thermal insulation effect.Since the thermal insulation member 100 is a closed structure formed by hot pressing after vacuuming, the thermal insulation member 100 has high strength, so that when the battery pack 200 is assembled, water does not leak from the thermal insulation member 100 due to the high pressure and it does not break, which has a positive effect on the quality of the battery pack 200.

[0063] With reference to Fig. 16, the embodiment of the present application further provides a vehicle 300 including a drive device 310 and the battery pack 200 in the above embodiment, wherein the battery pack 200 is configured to supply power to the drive device 310.

[0064] Those skilled in the art should appreciate that the above embodiments are illustrative only of the present application and are not intended to limit the present application. To the extent that they are within the spirit and scope of the present application, corresponding changes and modifications to the above embodiments are within the scope of the present application.

Claims

[1] A thermal insulation element, characterized by that it includes: a heat-insulating core material, the heat-insulating core material comprising a bottom surface and a surface arranged opposite each other, two opposite side surfaces, and two opposite end surfaces connected between the bottom surface and the surface; and a film material wrapped around the outside of the heat-insulating core material to encapsulate the heat-insulating core material, wherein the film material is folded from the bottom surface along both side surfaces to the surface and at least partially overlapped on the surface to form a first overlap portion. Among them, the film material also forms a second overlap portion on each of the two end surfaces, and the second overlap portion includes a first overlap layer, a second overlap layer, and a third overlap layer stacked one after the other; the first overlap layer is folded from the side surface to the heat-insulating core material; the second overlap layer is folded from the surface to the end surface and at least partially covers the first overlap layer; the third overlap layer is folded from the bottom surface to the end surface and at least partially covers the second overlap layer; the film material further forms a first lamination portion extending from the third overlap layer to the surface and abutting against the film material on the surface. [2] Thermal insulation element according to claim 1, characterized bythat the film material comprises a base material layer and an adhesive layer, wherein the adhesive layer is arranged on one side of the base material layer and is designed to connect a part of the film material to a part of the heat-insulating core material and to bond parts of the film materials to one another. [3] Thermal insulation element according to claim 1, characterized by in that the film material further comprises a second laminating portion formed between the second overlap layer and the third overlap layer, the second laminating portion being formed by extending from the second overlap layer and being bonded to the third overlap layer. [4] The thermal insulation element according to claim 3, characterized by that a length of the second lamination portion in a direction away from the second overlap layer is greater than 3 mm. [5] The thermal insulation element according to claim 1, characterized by that the length of the first lamination section in a direction away from the third overlap layer is greater than 3 mm. [6] The thermal insulation element according to claim 1, characterized by that the first overlap region comprises an overlap section and a reinforcement region and the width of the reinforcement region is greater than the width of the overlap region. [7] Thermal insulation element according to claim 1, characterized byin that the film material, in the unfolded state, is defined by a bottom surface fastening region, a side surface fastening region, a surface fastening region, a first overlap region, a second overlap region, a third overlap region, a first lamination region, and a second lamination region; wherein the side surface fastening regions are arranged on both sides of the bottom surface fastening region along the first direction, and the surface fastening region is arranged on a side of the side surface fastening region facing away from the bottom surface fastening region; wherein the third overlap section is arranged on both sides of the bottom surface fastening region along the second direction; wherein the first lamination region is arranged on a side of the third overlap section facing away from the bottom surface fastening region;wherein the first overlap portion is arranged on both sides of the side attachment region along the second direction, wherein the second overlap portion is arranged on both sides of the ; O surface attachment region is arranged along the second direction; the second lamination region, in the unfolded state, is located at the four corners of the film material and borders the second overlap portion. [8] Thermal insulation element according to claim 7, characterized bythat first notches are opened at the four corners of the film material and the film material is defined at the position of each of the first notches with a first edge and a second edge; wherein the first edge is parallel to the first direction and is located at least on a side of the second lamination area facing away from the second overlap area; wherein the second edge is parallel to the second direction and does not overlap with the subsurface attachment area at least in the first direction. [9] Thermal insulation element according to claim 7, characterized byin that first notches are opened at the four corners of the film material and the film material is defined at the position of each of the first notches with a first edge and a second edge; wherein the first edge is parallel to the first direction and is located at least on a side of the second laminating area facing away from the second overlap area, wherein the end point at which the second edge is connected to the first edge is located in the third overlap area, and the second edge extends in the first direction in a direction away from the first edge, and the angle between the second edge and the second direction is 22.5° to 32.5°. [10] Thermal insulation element according to claim 1, characterized bythat second notches are opened at the four corners of the film material, the second notches being adapted to form an exposed area exposing the surface after the film material has been folded onto the surface, the exposed area being covered by the first laminating section. [11] Thermal insulation element according to claim 1, characterized by that the thermally insulating core material comprises one or more superpositions of a fiber material layer, a fiber-reinforced aerogel composite material layer, a phase change material layer, an expansion material layer and an elastic layer. [12] A battery pack, characterized by that it includes: several battery cells; and at least one thermal insulation element as described in any one of claims 1 to 11, wherein one or more of the thermal insulation elements are arranged between two adjacent battery cells; and / or they are arranged on a side of the battery cell facing away from another battery cell. [13] A vehicle, characterized by that it includes: a drive device; and The battery pack according to claim 12, wherein the battery pack is configured to supply power to the drive device.

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