Shielding article

Abstract

To provide a battery pack having improved flame retardancy and reduced fire spread.SOLUTION: A graphite article (RFPE) 100 includes first and second flexible graphite sheets 101, each flexible graphite sheet having a thickness of at least 0.25 mm and a thermal conductivity of at least 300 W / mK, and a core 102 having a foam and at least one flame-retardant material, and the at least one flame-retardant material includes expandable graphite, and the first and second flexible graphite sheets are arranged on opposite sides of the core, but are not in direct contact with each other. The graphite article is positioned either inside or outside the battery housing.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to shielding articles. [Background technology]

[0002] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 043,468, filed June 24, 2020, and U.S. Provisional Patent Application No. 63 / 068,452, filed August 21, 2020, the entire contents of which are incorporated herein by reference.

[0003] As lithium-ion batteries become more prevalent in society, the risks associated with using them are also becoming more well known. Summary of the Invention [Problem to be solved by the invention]

[0004] One example of a risk is that the electrolyte in lithium-ion batteries is known to be flammable. Lithium-ion batteries are known to exhibit advantageous properties for generating large amounts of energy, but are also known to pose a risk of fire and / or explosion, for example in Tesla electric vehicles, as well as consumer devices such as hoverboards, e-cigarette devices or mobile phones. [Means for solving the problem]

[0005]

[0003] Embodiments disclosed herein relate to battery packs with improved flame retardancy / reduced fire spread. Such battery packs include a battery housing (AKA casing or enclosure). The housing may include a bottom surface, one or more vertical surfaces, and a lid. The battery housing includes a plurality of battery cells. The battery cells are disposed above the bottom surface and below the lid, and are further surrounded by one or more vertical surfaces.

[0006] The system may further include a flame retardant / fire spread reduction element. One example of such an element may include a pair of flexible graphite outer layers and a foam core. The flexible graphite outer layers are on either side of the core. Preferably, the flexible graphite layers are not in substantial physical contact. More preferably, the flexible graphite layers are separated by the foam core. The foam core may include one or more flame retardant elements. One such flame retardant element may include an intumescent element, such as expandable graphite.

[0007] The application of the flame retardant element / fire spread reduction element is not limited to use in battery packs. The element applies to any system where it is desirable to reduce the spread of fire.

[0008] The subject matter is further disclosed in the detailed description. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is an exemplary article according to the present disclosure comprising two flexible graphite sheets attached to a core. [Figure 2] 1 is an exemplary article according to the present disclosure comprising one flexible graphite sheet attached to an insulation layer. [Figure 3] 1 is an exemplary article according to the present disclosure, including one graphite-doped silicone layer attached to an insulating layer. [Figure 4] 1 is an exemplary article according to the present disclosure that includes two insulating layers (of the same or different materials) attached to a single flexible graphite sheet. [Figure 5] 2 is an exemplary article according to the present disclosure that includes an article according to FIG. 1 but also includes at least one metal backing layer. [Figure 6] 2 is an exemplary article according to the present disclosure that includes an article according to FIG. 1 but also includes at least one electrically insulating layer. [Figure 7A]2 is an exemplary battery pack according to the present disclosure including within a battery housing battery cells and articles according to FIG. 1. Each of the articles according to FIG. 1 contacts at least one side of the battery housing. [Figure 7B] 2 is an exemplary battery pack according to the present disclosure including battery cells and articles according to Fig. 1 within a battery housing, each article according to Fig. 1 contacting two or more sides of the battery housing. [Figure 8A] 2 is an exemplary battery pack according to the present disclosure, including within a battery housing battery cells and articles according to FIG. 1. Each of the articles according to FIG. 1 contacts at least one side of the battery housing or between adjacent battery cells. [Figure 8B] 2 is an exemplary battery pack according to the present disclosure, including within a battery housing battery cells and articles according to Fig. 1. Each article according to Fig. 1 contacts two or more sides of the battery housing or between adjacent battery cells. [Figure 9] 2 is an exemplary battery pack according to the present disclosure including battery cells and articles according to FIG. 1 in contact on two or more sides of the exterior of the battery housing and between adjacent battery cells. [Figure 10] 2 is an exemplary battery pack according to the present disclosure including a battery cell and article according to FIG. 1 inside a battery housing in contact with two or more sides of the exterior of the battery housing and in contact with a vertical side of the battery housing. [Figure 11] 2 is an exemplary battery pack according to the present disclosure including the battery cell and article according to FIG. 1, with contact between all sides within the battery housing and all sides of adjacent battery cells. [Figure 12A] FIG. 1 is a side view of Sample A of the embodiment at the end of the test. [Figure 12B] FIG. 10 is a side view of Sample B of the example at the end of the test. [Figure 12C] FIG. 10 is a side view of Sample C of the example at the end of the test. [Figure 12D] FIG. 10 is a side view of Sample D of the example at the end of the test. [Figure 12E] FIG. 10 is a side view of Sample E of the example at the end of the test. [Figure 13A] 1 is a chart showing the temperature profile of Sample A of the example. [Figure 13B] 1 is a chart showing the temperature profile of Sample B of the example. [Figure 13C] 1 is a chart showing the temperature profile of Sample C of the example. [Figure 13D] 1 is a chart showing the temperature profile of Sample D of the example. [Figure 13E] 1 is a chart showing the temperature profile of Sample E of the example. [Figure 14] 1 is a chart of the temperature profile of the control in the example. DETAILED DESCRIPTION OF THE INVENTION

[0010] The graphite articles (RFPE) disclosed herein are disclosed for use in battery packs. However, the graphite articles disclosed herein have application in any environment where reduced fire spread is desirable, such as vehicle firewalls, insulation or casings for battery-powered devices, energy storage systems, rapid release of energy shields, or insulating elements for heating equipment.

[0011] The battery packs disclosed herein are not limited to any particular type of battery. Examples of suitable battery cells that can be used to implement the present disclosure include cylindrical batteries, pouch batteries, prismatic batteries, or any combination thereof.

[0012] In general terms, a power system for a battery-powered device includes a battery pack 700, 800, 900, 1000, 1100, as shown in Figures 7-11, which is the overall power element for the device. The pack includes a battery housing 702 consisting of multiple surfaces, e.g., a bottom, a lid, and one or more vertical surfaces. The housing surfaces are aligned to surround (enclose) a plurality of cells 701. The battery pack may include other elements as needed. Examples of such elements may include a heat sink or a cooling plate.

[0013] Disclosed herein are reduced fire propagation elements ("RFPEs"). RFPE elements can be utilized in conjunction with or within battery packs. FIGS. 7-11 show examples of how RFPE elements can be used in connection with battery packs. FIG. 9 shows that RFPEs can be disposed on one or more exterior surfaces of battery cells 701, for example, between adjacent vertical faces of adjacent battery cells 701, on the exterior surface of a housing lid, and on the exterior surface of a housing bottom.

[0014] If desired, RFPE may be applied to more than one surface of the battery housing 702. As shown in Figure 10, a first RFPE may be applied to the exterior surface of the lid, a second RFPE may be applied to the exterior surface of the bottom, and a third RFPE may be applied to each vertical surface of the housing 702, which may be interior (shown) or exterior (not shown). The use of more than one RFPE on the battery housing 702 is not limited to the listed examples and is merely illustrative of the possibilities.

[0015] In connection with or alternatively to the above, an RFPE may be included in the battery housing 702 of the battery pack. The RFPE may be disposed inside the battery housing 702. In FIGS. 7-11, the RFPEs may be used separately or in any combination thereof. The RFPE may be disposed (1) on the inner surface of the lid of the battery housing 702, (2) on the inner surface of the bottom of the battery housing 702, (3) on one or more vertical surfaces of the housing 702, and / or (4) between two adjacent battery cells 701.

[0016] If attachment between the RFPE and the surface of the battery housing is desired, the RFPE may be glued to the surface of the battery housing 702. Any type of adhesive may be used. Depending on the desired application, the adhesive may be a high temperature adhesive; two examples are phenolic resin or carbonizable cement.

[0017] Various embodiments of RFPEs are disclosed herein, and each and every one of the RFPE embodiments disclosed herein is equally applicable to the applications discussed above.

[0018] According to the present disclosure, an RFPE is an article comprising at least one graphite sheet. In other words, in an exemplary embodiment, the RFPE comprises a graphite article. Preferably, the RFPE comprises first and second flexible graphite sheets 101. The first and second graphite sheets may be the same graphite sheet 101 or different graphite sheets 101(a) and 101(b) (not shown). At least one of the flexible graphite sheets 101 preferably has a thermal conductivity of at least about 300 W / mK to about 2000 W / mK. In certain embodiments, both of the flexible graphite sheets have a thermal conductivity of at least about 300 W / mK to about 2000 W / mK. The flexible graphite sheets may or may not have the same thermal conductivity. An exemplary preferred electrical conductivity may range from at least about 300 W / mK to about 1200 W / mK. Specific examples of suitable thermal conductivities may include at least about 300 W / mK, at least about 350 W / mK, at least about 400 W / mK, at least about 450 W / mK, at least about 500 W / mK, at least about 800 W / mK, at least about 1000 W / mK, and at least about 1200 W / mK. All of the foregoing thermal conductivities are in-plane thermal conductivities.

[0019] 1 shows an embodiment of an RFPE 100 of the present disclosure, in which only one flexible graphite sheet 101(a) has a thermal conductivity of at least 300 W / mK to 2000 W / mK, and such graphite sheet 101(a) has a density of at least 1.4 g / cc to 2.1 g / cc. Meanwhile, flexible graphite sheet 101(b), having a thermal conductivity of 300 W / mK to 250 W / mK, has a density of 1.3 g / cc to 1.0 g / cc. In this embodiment, preferably, flexible graphite sheet 101(b), having a density less than 1.3 g / cc, is adjacent to the surface of the battery housing.

[0020] The flexible graphite sheets 101 disclosed herein may include one or more flexible graphite sheets of compressed particles of exfoliated graphite particles, graphitized polyimide, and combinations thereof.

[0021] The thickness of the flexible graphite sheet 101 may range from at least about 80 microns to about 2 mm. Exemplary thicknesses may be any of the following, as well as dimensions not listed in the ranges above but within the ranges above: at least about 100 microns, at least about 150 microns, at least about 250 microns, at least about 500 microns, at least about 750 microns, at least about 1 mm, and at least about 1.5 mm.

[0022] The flexible graphite sheets 101 disclosed herein do not have to have the same properties, such as, but not limited to, a first flexible graphite sheet 101(a) may have a greater or lesser thickness than a second flexible graphite sheet 101(b). This also applies to other properties of the graphite sheets. Alternatively, the flexible graphite sheet 101 may have the same property or at least three properties that are the same.

[0023] The RFPE includes a core 102. The core 102 may include foam and at least one flame-retardant material. Multiple flexible graphite sheets 101 may be disposed on opposing sides of the core 102, with the sheets only in minimal direct contact with each other. Unless otherwise specified, "minimal direct contact with each other" refers to less than 10% of the total area of ​​one graphite sheet being in direct contact with the other, and preferably less than 5% of the total area of ​​one graphite sheet being in direct contact with the other. Preferably, the flexible graphite sheets 101 do not contact each other. This minimal or no direct contact prevents heat transfer from the hot side to the cold side of the RFPE.

[0024] The thickness of the core 102 may vary depending on the application of the RFPE. The thickness may be limited due to space limitations in a particular device. Another factor that may be related to the thickness is the insulation value (R-value) of the core 102. The thickness of the core 102 may be increased if more insulation is desired, or may be decreased depending on the R-value of the material of construction of the core 102.

[0025] Exemplary thicknesses of the core 102 utilized in or within the battery packs 700, 800, 900, 1000, and 1100 may range from at least 20 microns to 10 mm. In particular examples, the thickness of the core 102 includes 5 mm or less.

[0026] Examples of foam core materials of construction may include ceramic precursors and / or foamed polymeric materials, such as polyurethane, ethylene-vinyl acetate ("EVA") foam, acrylonitrile butadiene rubber (NBR), polyvinyl chloride (PVC) or polyisocyanate compounds, and mixtures thereof.

[0027] Non-limiting examples of suitable ceramic precursors include silicon carbide (SiC), silicon oxycarbide (SiO x C y ), silicon nitride (Si3N4), silicon carbonitride (Si 3+x N4C x+y ) and silicon oxynitride (SiO x N y ) and silicon-yielding compounds such as silicone foams formed from at least one of the above.

[0028] One embodiment of the foam comprises up to 30% NBR, up to 30% PVC, and up to 30% ceramic precursor, in this example percentages are by weight.

[0029] The foam may, but need not necessarily, be a syntactic, reticulated or closed-cell foam.

[0030] Other constituent materials for the core foam include foamed elastomers and / or thermoplastic elastomer blends based on styrene-based organic polymers and chlorinated organic polymers. The foamed elastomer or thermoplastic elastomer blend itself contains a styrene-substituted organic polymer, preferably a styrene-butadiene polymer. The styrene-substituted polymer exhibits a styrene content of at least 10%, preferably at least 17%, and particularly preferably 20% or more (bound styrene according to ASTM D5775). The styrene-substituted organic polymer is present in the formulation in an amount of at least 30 phr (per hundred rubber, meaning that it represents at least 30 percent of the elastomer content of the claimed material), preferably at least 50 phr, and particularly preferably at least 70 phr.

[0031] The elastomer or thermoplastic elastomer blend further comprises at least 10 phr, preferably at least 30 phr, and particularly preferably at least 50 phr of a thermoplastic or thermoplastic elastomeric chlorinated organic polymer (relating to the styrene-substituted polymer), preferably polyvinyl chloride (PVC), chlorinated polyethylene (CPE, CM), chlorosulfonated polyethylene (CSM), or any mixture thereof. Furthermore, the elastomer or thermoplastic elastomer blend further comprises at least 30 phr, preferably 50 phr, and particularly preferably 70 phr, of a halogenated paraffin, halogenated fatty acid-substituted glycerin, or any combination thereof (representing oils and / or fats and / or waxes), preferably chloroparaffins and / or chlorinated fatty acid-substituted glycerin, particularly preferably long-chain chlorinated paraffins (C>17) and / or glycerin substituted with at least C>8 fatty acids. The chlorination degree of the chlorinated paraffins and / or fatty acid-substituted glycerin is at least 15 percent, preferably at least 20 percent, and particularly preferably at least 30 percent.

[0032] The elastomer or thermoplastic elastomer mixture may also contain at least 30 phr, preferably at least 100 phr, particularly preferably more than 200 phr, of inorganic fillers, preferably of metal and / or semimetal chalcogen (i.e., compounds of oxygen, sulfur) nature. The inorganic fillers may be aluminum compounds, such as aluminum silicates, oxides, hydroxides, etc., such as ATH (aluminum trihydroxide), and / or silicone compounds, such as silicates, quartz, zeolites, or corresponding minerals, such as gypsum, clay, perlite, vermiculite, chalk, slate, graphite, talc / mica, etc., or mixtures thereof.

[0033] The elastomer or thermoplastic elastomer blend has a closed cell content of at least 80% and a thermal conductivity of 100 kg / m according to ISO 845 in order to reduce the thermal conductivity to less than 0.075 W / mK at 0°C, preferably less than 0.040 W / mK at 0°C, particularly preferably less than 0.035 W / mK at 0°C, in accordance with EN 12667. 3 less than 65 kg / m 3 less than 50 kg / m 3 It is foamed into a predominantly closed-cell foam having a density less than 1000 MPa.

[0034] An example embodiment of a foamed polymer material includes at least 300 phr, but can include less than 1000 phr of components totaling 100 phr, including 100 phr of at least two polymers, of which (1) at least 55 phr is polyvinyl chloride (PVC) or vinyl chloride copolymer or vinyl chloride terpolymer or mixtures thereof, and (2) at least 10 phr is at least one additional chlorinated organic polymer crosslinked with sulfur and / or metal oxide and / or thiadiazole derivative.

[0035] The elastomer or thermoplastic elastomer blend may contain further additives, such as flame retardants and synergists, biocides, plasticizers, stabilizers (e.g., against UV, ozone, reversion, etc.), colorants, in any proportion, for example additives to improve its production, application, aspect and performance properties, inhibitors, retarders, accelerators, etc.; and / or additives adapted to the needs of the application, such as char-forming additives and / or intumescent additives, such as expandable graphite, which cause the material to self-expand in the event of a fire (e.g., for general protection purposes and / or, for example, to close and protect penetrations in side walls and bulkheads); and / or substances that self-ceramize in the event of a fire, such as boron compounds, silicon-containing compounds; and / or internal adhesion promoters, such as silicate acid esters, functional silanes, polyols, etc., to ensure self-adhesion in coextrusion and co-lamination applications.

[0036] In embodiments to achieve sufficient fire resistance and low smoke generation, the use of non-halogenated polymers should be limited to less than 30 phr, preferably less than 20 phr, and most preferably less than 10 phr. The feasible amount of non-halogenated polymer depends on the required fire and smoke performance due to its impact on the fire load, as well as the required size and density of the material.

[0037] The core 102 may also include one or more flame-retardant materials. A preferred type of flame-retardant material is an intumescent material. A suitable type of intumescent material includes expandable graphite. Expandable graphite may be used in conjunction with one or more other flame-retardant materials. Other suitable flame-retardants include at least one of Mg(OH)3, alumina trihydrate (ATH), ammonium polyphosphate (APP), melamine polyphosphate (MPP), zinc borate, and combinations thereof.

[0038] Properties of suitable expandable graphite include an onset temperature of at least about 160° C. Typically, the onset temperature is no greater than 350° C. Typical onset temperatures can be at least about 180° C., at least about 200° C., at least about 220° C., at least about 250° C., or at least about 280° C.

[0039] The particle size of the expandable graphite may include at least about 325 mesh. The particle size may range up to about 20 mesh, as well as any and all combinations of particle sizes between about 325 mesh and about 20 mesh, which in microns is a range of about 44 to 850 microns. Other examples of suitable particle sizes include 50 mesh or 80 mesh expandable flake graphite.

[0040] A suitable loading level of the core 102 with expandable graphite may include at least about 2% by weight (pbw) of expandable graphite. Maximum loading levels may be up to about 50 (50%) pbw. Any range between 2% and 50% by weight is acceptable, such as 2-40%, 2-30%, 2-20%, 2-10%, 5-40%, 5-30%, 5-20%, 5-10%, etc. Pbw is used herein to mean weight percent of the entire article.

[0041] According to the present disclosure, flexible graphite sheets 101 may be attached to core 102. Preferably, flexible graphite sheets 101 are glued to core 102. Any suitable type of adhesive may be used. The above discussion regarding adhesives is incorporated herein. Optionally, a fire-resistant adhesive may be used to glue each flexible graphite sheet 101 to core 102, if desired. In a further option, a fire-resistant adhesive may be used to glue one of flexible graphite sheets 101 to core 102, and a non-fire-resistant adhesive may be used with the other flexible graphite sheet 101 to glue it to core 102. In embodiments where two types of adhesives are used, the non-fire-resistant adhesive is preferably adjacent to a face of battery housing 602. In other words, the fire-resistant adhesive is adjacent to the plurality of battery cells 601.

[0042] Preferably, the RFPE does not have one or more structural supports between flexible graphite sheets 101. This description is for all embodiments of the RFPE disclosed herein and those considered within the scope of this disclosure.

[0043] Referring to another embodiment, the core 102 may include an insulating material including a material other than a foam material and, optionally, at least one flame-retardant material. The core material may include one or more of mica, aerogel, woven mesh, silicone, ceramic, fiberglass, carbon fiber, mineral wool such as high-temperature mineral wool such as Kaoru wool, gypsum board, concrete, titanium, nickel alloys (such as, but not limited to, HASTELLOY), and combinations thereof. The above disclosure regarding flame-retardant materials is equally applicable to cores including materials other than foam.

[0044] RFPE 400 of the present disclosure, shown in FIG. 4, may include an insulating material as outer layer 201 and flexible graphite as core layer 101. In another embodiment, shown in FIG. 2, RFPE 200 includes at least one flexible graphite sheet 101 attached to insulation layer 201. In another embodiment, shown in FIG. 3, in RFPE 300, flexible graphite sheet 101 (not shown in FIG. 3) of RFPE 200 may be replaced by or used in combination with graphite-doped silicone layer 301 adjacent to insulation layer 201. The graphite additive for doping the silicone layer may include graphite powder, expandable graphite powder, or a combination thereof.

[0045] The RFPE 500 shown in FIG. 5 may include a metal backing layer 501 adjacent to one of the flexible graphite sheets 101. Suitable types of metal include steel, aluminum, copper, and alloys thereof. The RFPE 600 shown in FIG. 6 may include an electrically isolating layer 601. In any embodiment that includes an electrically isolating layer 601, the electrically isolating layer 601 is the outermost layer. An example of a suitable material for forming the electrically isolating layer 601 may include polyimide.

[0046] An advantage of the RFPE disclosed herein is improved suppression of fire spread. The RFPE disclosed herein can be used to provide suppressed fire spread in articles of manufacture for up to 50 minutes at temperatures up to 350°C.

[0047] Example Various samples were tested for reduction in fire spread.

[0048] The compositions and controls of the five sample configurations according to the RFPE disclosed herein are as follows: Sample A. Flexible graphite - 250 micron aerogel - flexible graphite (approximately 4.5 mm thick) (shown in Figure 12A) Sample B. Flexible graphite-ceramic wool and mica layer-flexible graphite (approximately 4.5 mm thick) (shown in Figure 12B) Sample C. Flexible graphite-woven mesh and mica layer-flexible graphite (approximately 3.3 mm thick) (shown in Figure 12C) Sample D. Flexible graphite-silicone with expandable graphite-flexible graphite (approximately 3.85 mm thick) (shown in Figure 12D) Sample E. Flexible graphite-ceramic precursor foam with expandable graphite - flexible graphite (approximately 4.5 mm thick) (shown in Figure 12E) Control: Flexible graphite bonded to a steel plate (not shown).

[0049] Each flexible graphite sheet 101 had a thermal conductivity of 400 W / mK and a thickness of 0.94 mm. Each sample was bonded to a 0.59 mm thick piece of galvanized steel metal. A fire-resistant adhesive, such as Cotronics Resbond 907, was used to bind the components of each sample. The samples were layered and cured under low weight to ensure adhesion between adjacent layers.

[0050] Each sample is six (6") by six (6") inches.

[0051] The samples were secured in the test fixture. A heat source providing a flame of approximately 10,000 BTU (approximately 3,000 W) was used. Temperatures were measured at the center of the top (side opposite the flame) and bottom (side adjacent to the flame) of each sample. The flame temperature was approximately 800-900°C, while the bottom temperature was expected to be in the range of 500-600°C. Each sample was heated for 50 minutes, and the temperature drop across the thickness of each sample was measured (delta (Δ)T between the bottom and top temperatures). The reported ΔT is the average obtained over the last 5 minutes of the 50-minute test period.

[0052] [Table 1]

[0053] Sample E, flexible graphite with expandable graphite-ceramic precursor foam-laminate with flexible graphite, exhibited a ΔT that was 10% (10%) greater than the closest other sample (Sample A) and the control, and more than 45% (45%) higher than the sample with the lowest ΔT (Sample C).

[0054] The temperature curves for each sample and control are shown in Figures 13A-13E and 14.

[0055] 12A-E show side views of Samples A-E. As shown for each sample containing expandable graphite, Samples D and E, the graphite expands, thereby forming a char layer and providing the benefit of volume expansion.

[0056] The disclosures of all cited patents and publications mentioned in this application are incorporated herein by reference in their entirety. The various implementations disclosed herein can be practiced in any combination thereof. The above description is intended to enable one skilled in the art to practice the invention. It is not intended to detail all possible variations and modifications that will become apparent to those skilled in the art upon reading the description. However, all such modifications and variations are intended to be included within the scope of the invention as defined by the following claims. The claims are intended to cover the shown elements and steps in any arrangement or sequence that is effective to fulfill the object intended for the invention, unless the context specifically dictates otherwise.

[0057] All references in this disclosure to singular features or limitations shall include the corresponding plural features or limitations, and vice versa, unless otherwise specified or clearly suggested to the contrary by the context in which the reference is made. Accordingly, in this disclosure, the word "a" or "an" shall be construed to include both the singular and the plural. Conversely, references to plural items shall, where appropriate, include the singular.

[0058] Unless otherwise indicated (e.g., by use of the term "exactly"), all numbers expressing quantities, properties, such as molecular weight, reaction conditions, and the like, used in the specification and claims are to be understood as being modified in all instances by the term "about." Accordingly, unless otherwise indicated, the numerical properties set forth in the following specification and claims are approximations that may vary depending upon the desired properties sought to be obtained in embodiments of the present invention.

[0059] Unless otherwise specified herein, thermal conductivity is provided at room temperature and standard pressure (1 atmosphere), or alternatively, at appropriate test conditions if a standard test protocol is known, such as ASTM D5470 for planar conductivity of flexible graphite articles.

[0060] All combinations of method or process steps used herein can be performed in any order unless otherwise specified or clearly implied by the context in which the referenced combination is made.

[0061] All ranges and parameters disclosed herein, including but not limited to percentages, parts, and ratios, are understood to encompass any and all subranges contemplated and encompassed therein, as well as all numbers between the endpoints. For example, a stated range of "1 to 10" should be considered to include any and all subranges between (and including) the minimum value of 1 and the maximum value of 10, i.e., beginning with a minimum value of 1 or more (e.g., 1 to 6.1) and ending with a maximum value of 10 or less (e.g., 2.3 to 9.4, 3 to 8, 4 to 7), and ultimately up to and including each number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 included within the range.

[0062] The shielding articles of the present disclosure can include, consist of, or consist essentially of the essential elements and limitations of the present disclosure described herein, as well as any additional or optional ingredients, components, or limitations described herein or useful in shielding articles.

[0063] To the extent the terms "include," "includes," or "including" are used in this specification or the claims, they are intended to be inclusive in a manner similar to the term "comprising" when interpreted as such terms are used as transitional terms in the claims. Furthermore, to the extent the term "or" (e.g., A or B) is used, it is intended to mean "A or B or both A and B." Where applicant intends to indicate "only A or B, but not both," the term "only A or B, but not both" is used. Thus, the use of the term "or" herein is inclusive, not exclusive.

[0064] Illustrative Embodiments

[0065] 1.a. first and second flexible graphite sheets, each flexible graphite sheet having a thickness of at least 0.25 mm and a thermal conductivity of at least 300 W / mK; b. a core comprising foam and at least one flame retardant material; Equipped with Flexible graphite sheets placed on opposite sides of the core have minimal direct contact with each other Goods.

[0066] 2. The core thickness is 10mm or less The article of exemplary embodiment 1.

[0067] 3. The foam comprises at least one of a ceramic precursor, a polyurethane ethyl vinyl acetate, or a polyisocyanate compound. The article of exemplary embodiment 1 or 2.

[0068] 4. The ceramic precursor is one of the following compounds: silicon carbide (SiC), silicon oxycarbide (SiO x C y), silicon nitride (Si3N4), silicon carbonitride (Si 3+x N4C x+y ) and silicon oxynitride (SiO x N y ) and at least one of the combinations thereof The article of Exemplary Embodiment 3.

[0069] 5. The core has a thickness of 5 mm or less, and each flexible graphite sheet has a thickness of at least 0.5 mm. The article of exemplary embodiment 1, 2, 3 or 4.

[0070] 6. Flame retardant contains expandable graphite The article of exemplary embodiment 1, 2, 3, 4 or 5.

[0071] 7. The expandable graphite loading level is at least 2% by weight The article of Exemplary Embodiment 6.

[0072] 8. The loading level of expandable graphite is 50% by weight or less The article of exemplary embodiment 6 or 7.

[0073] 9. The starting temperature of the expandable graphite is at least 160°C The article of exemplary embodiment 6, 7, or 8.

[0074] 10. The starting temperature of expandable graphite is less than 350℃ The article of exemplary embodiment 6, 7, or 8.

[0075] 11. The expandable graphite has a size of at least 325 mesh The article of exemplary embodiment 6, 7, 8, 9 or 10.

[0076] 12. Contains 20 or fewer meshes The article of exemplary embodiment 6, 7, 8, 9, 10, or 11.

[0077] 13. The flame retardant contains at least one other flame retardant in addition to expandable graphite. The article of exemplary embodiment 6, 7, 8, 9, 10, 11, or 12.

[0078] 14. One other flame retardant includes at least one of Mg(OH)3, alumina trihydrate (ATH), ammonium polyphosphate (APP), melamine polyphosphate (MPP), zinc borate, and combinations thereof. 14. The article of Exemplary Embodiment 13.

[0079] 15. No more than one structural support between flexible graphite sheets The article of any one of Exemplary Embodiments 1-14.

[0080] 16.a. first and second flexible graphite sheets, each flexible graphite sheet having a thickness of at least 0.25 mm and a thermal conductivity of at least 300 W / mK; b. a core comprising at least one flame retardant material and an insulating material comprising at least one of mica, aerogel, woven mesh, silicone resin, glass fiber, carbon fiber, mineral wool, gypsum board, concrete, titanium, nickel alloy, and combinations thereof; and at least one flame retardant material; Equipped with Flexible graphite sheets placed on opposite sides of the core have minimal direct contact with each other Goods.

[0081] 17. The core has a thickness of 5 mm or less, and each flexible graphite sheet has a thickness of at least 0.5 mm. The article of Exemplary Embodiment 16.

[0082] 18. Flame retardant contains expandable graphite The article of Exemplary Embodiment 16.

[0083] 19. The loading level of expandable graphite is at least 2% by weight. The article of Exemplary Embodiment 18.

[0084] 20. The fill level of expandable graphite is 50% by weight or less The article of Exemplary Embodiment 18.

[0085] 21. The onset temperature of the expandable graphite is at least 160°C. The article of exemplary embodiment 18, 19, or 20.

[0086] 22. The starting temperature of expandable graphite is less than 350°C The article of exemplary embodiment 18, 19, or 20.

[0087] 23. The expandable graphite has a size of at least 325 mesh. The article of exemplary embodiment 18, 19, 20, 21, or 22.

[0088] 24. Contains 20 or fewer meshes The article of exemplary embodiment 18, 19, 20, 21, 22, or 23.

[0089] 25. The flame retardant contains at least one other flame retardant in addition to expandable graphite. The article of exemplary embodiment 18, 19, 20, 21, 22, 23, or 24.

[0090] 26. One other flame retardant includes at least one of Mg(OH)3, alumina trihydrate (ATH), ammonium polyphosphate (APP), melamine polyphosphate (MPP), zinc borate, and combinations thereof. The article of exemplary embodiment 25.

[0091] 27. No more than one structural support between flexible graphite sheets The article of any one of Exemplary Embodiments 16-26.

[0092] 28.a. First and second flexible graphite sheets, each flexible graphite sheet having a thickness of at least 0.10 mm and a thermal conductivity of at least 300 W / mK; b. a core comprising foam and at least one flame retardant material; Equipped with Flexible graphite sheets placed on opposite sides of the core have minimal direct contact with each other Goods.

[0093] 29. The core thickness is 10 mm or less The article of exemplary embodiment 28.

[0094] 30. The foam comprises at least one of a ceramic precursor, a polyurethane ethyl vinyl acetate, or a polyisocyanate compound. 30. The article of exemplary embodiment 29.

[0095] 31. The ceramic precursor is one of the following compounds: silicon carbide (SiC), silicon oxycarbide (SiO x C y ), silicon nitride (Si3N4), silicon carbonitride (Si 3+x N4C x+y ) and silicon oxynitride (SiO x N y ) and at least one of the combinations thereof The article of exemplary embodiment 30.

[0096] 32. The core is 5 mm thick or less, and each flexible graphite sheet is at least 0.5 mm thick. The article of any one of Exemplary Embodiments 28-31.

[0097] 33. Flame retardant contains expandable graphite The article of exemplary embodiment 32.

[0098] 34. Expandable graphite loading level is at least 2% by weight The article of exemplary embodiment 33.

[0099] 35.Expandable graphite loading level is 50 wt.% The article of exemplary embodiment 33.

[0100] 36. The onset temperature of the expandable graphite is at least 160°C. 36. The article of exemplary embodiment 33, 34, or 35.

[0101] 37. The starting temperature of expandable graphite is less than 350°C. 36. The article of exemplary embodiment 33, 34, or 35.

[0102] 38. The expandable graphite has a size of at least 325 mesh. The article of any one of Exemplary Embodiments 33-37.

[0103] 39. Contains meshes with 20 or less meshes The article of any one of Exemplary Embodiments 33-38.

[0104] 40. The flame retardant contains at least one other flame retardant in addition to expandable graphite. The article of any one of Exemplary Embodiments 33-38.

[0105] 41. One other flame retardant includes at least one of Mg(OH)3, alumina trihydrate (ATH), ammonium polyphosphate (APP), melamine polyphosphate (MPP), zinc borate, and combinations thereof. The article of exemplary embodiment 40.

[0106] 42. No more than one structural support between flexible graphite sheets The article of any one of Exemplary Embodiments 28-41.

[0107] 43. An insulating layer having a thickness of at least 10 microns and capable of withstanding a temperature of at least 350°C for at least 50 minutes in an oxygen environment; a flexible graphite layer or a graphite-doped silicone composite having a thickness of at least 0.25 mm and a thermal conductivity of at least 300 W / mK; A composite article comprising:

[0108] 44. The insulating layer is made of talc, mica, aerogel, woven mesh, silicone resin, glass fiber, carbon fiber, ceramic fiber, ceramic wool, mineral wool, gypsum board, concrete, titanium, nickel alloy, or a combination thereof. 44. The composite article of exemplary embodiment 43.

[0109] 45. The insulating layer contains a fully dense insulator. 44. The composite article of exemplary embodiment 43.

[0110] 46. ​​The insulating layer contains a fire-resistant material 44. The composite article of exemplary embodiment 43.

[0111] 47. The thickness of the insulating layer is at least about 100 microns to about 10 mm. 47. The composite article of any one of Exemplary Embodiments 43-46.

[0112] 48. The thickness of the insulation is at least 1 mm 48. The composite article of any one of Exemplary Embodiments 43-47.

[0113] 49. The insulating layer includes at least one of inorganic fibers, non-metallic fibers, and combinations thereof. The composite article of any one of Exemplary Embodiments 43-48.

[0114] 50. The insulating layer is composed of at least one of alumina, zirconia, borate, silica, carbide, alloys thereof, and combinations thereof. 50. The composite article of any one of Exemplary Embodiments 43-49.

[0115] 51. The alloy contains nitrides 51. The composite article of exemplary embodiment 50.

[0116] 52. Further comprising a second insulating layer disposed adjacent to the flexible graphite layer, the graphite forming the core of the composite. 52. The composite article of any one of Exemplary Embodiments 43-51.

[0117] 53. The second insulating layer comprises at least one of the following groups: talc, mica, aerogel, woven mesh, silicone resin, glass fiber, carbon fiber, ceramic fiber, ceramic wool, mineral wool, gypsum board, concrete, titanium, nickel alloy, and combinations thereof. The article of exemplary embodiment 52.

[0118] 54. The second insulating layer comprises a fully dense insulator. 54. The composite article of exemplary embodiment 53.

[0119] 55. The second insulating layer comprises a fire-resistant material. 55. The composite article of exemplary embodiment 54.

[0120] 56. The thickness of the second insulating layer is at least about 100 microns to about 10 mm. 56. The composite article of any one of Exemplary Embodiments 52-55.

[0121] 57. The thickness of the second insulator is at least 1 mm. The composite article of any one of Exemplary Embodiments 52-56.

[0122] 58. The second insulating layer includes at least one of inorganic fibers, non-metallic fibers, and combinations thereof. The composite article of any one of Exemplary Embodiments 52-57.

[0123] 59. The second insulating layer is composed of at least one of alumina, zirconia, borate, silica, carbide, alloys thereof, and combinations thereof. The composite article of any one of Exemplary Embodiments 52-58.

[0124] 60. The alloy contains nitrides 60. The composite article of exemplary embodiment 59.

[0125] 61. The insulating layer does not contain an organic binder The composite article of any one of Exemplary Embodiments 43-55.

[0126] 62. The second insulating layer does not contain an organic binder. 62. The composite article of any one of Exemplary Embodiments 53-61.

[0127] 63. The composite article of any one of Exemplary Embodiments 43-62, further comprising a metal backing layer. Shielding articles.

[0128] 64. Further provided with an electrically insulating outermost layer 64. The shielding article of exemplary embodiment 63.

[0129] 65.a. A battery housing having two or more sides; b. a plurality of battery cells disposed within a battery housing; c. contacts at least one of two or more surfaces of the battery housing; The article of any one of exemplary embodiments 43 to 63; A battery pack comprising:

[0130] 66. The item is placed on either the inside or outside face of the battery housing. 66. A battery pack as described in exemplary embodiment 65.

[0131] 67.a. A battery housing having two or more sides; b. a plurality of battery cells disposed within a battery housing; c. the first and second articles of any one of exemplary embodiments 43-64; and Equipped with the first article contacts at least one of the two or more surfaces of the battery housing; The second item contacts a different surface of the battery housing than the first item. Battery pack.

[0132] 68.a. A battery housing having two or more sides; b. a plurality of battery cells disposed within a battery housing; c. the first and second articles of any one of exemplary embodiments 43-64; and Equipped with a first item contacting at least one of the two or more surfaces of the battery housing; The second item is disposed between two adjacent battery cells. Battery pack.

[0133] 69.a. A battery housing having two or more sides; b. a plurality of battery cells disposed within a battery housing; c. contacts at least one of two or more surfaces of the battery housing; An article according to any one of the exemplary embodiments; A battery pack comprising:

[0134] 70. The item is placed on either the inside or outside of the face of the battery housing. 70. The battery pack of exemplary embodiment 69.

[0135] 71.a. A battery housing having two or more sides; b. a plurality of battery cells disposed within a battery housing; c. a first and a second article according to any one of claims 1 to 4; Equipped with the first article contacts two or more sides of the battery housing; The second item contacts a different surface of the battery housing than the first item. A battery pack comprising:

[0136] 72.a. A battery housing having two or more sides; b. a plurality of battery cells disposed within a battery housing; c. a first and a second article according to any one of claims 1 to 4; Equipped with the first article contacts two or more sides of the battery housing; The second item is disposed between two adjacent battery cells. Battery pack.

Claims

1. a. first and second flexible graphite sheets, each flexible graphite sheet having a thickness of at least 0.25 mm and a thermal conductivity of at least 300 W / mK; b. a core comprising foam and at least one flame retardant material; Equipped with the at least one flame retardant material comprises expandable graphite; The first and second flexible graphite sheets disposed on opposite sides of the core do not directly contact each other or have minimal direct contact with each other. Goods.

2. 10. The article of claim 1 The amount of the expandable graphite filled is 50% by mass or less based on the total mass of the core. Goods.

3. 3. The article of claim 1 or 2, The expandable graphite has an expansion start temperature of at least 160°C and less than 350°C. Goods.

4. The article according to any one of claims 1 to 3, The expandable graphite has a particle size of at least 325 mesh and no greater than 20 mesh. Goods.

5. The article according to any one of claims 1 to 4, The at least one flame retardant material is Mg(OH) ３ , alumina trihydrate (ATH), ammonium polyphosphate (APP), melamine polyphosphate (MPP), zinc borate, or a combination thereof. Goods.

6. The article according to any one of claims 1 to 5, The foam comprises at least one of a ceramic precursor, a polyurethane ethyl vinyl acetate, or a polyisocyanate compound. Goods.

7. The ceramic precursor comprises at least one of silicon carbide, silicon oxycarbide, silicon nitride, silicon carbonitride, silicon oxynitride, or a combination thereof. The article according to any one of claims 1 to 6.

8. an insulating layer having a thickness of at least 10 microns; an insulating layer capable of withstanding a temperature of at least 350° C. for at least 50 minutes in an oxygen environment; a flexible graphite layer or a graphite-doped silicone composite having a thickness of at least 0.25 mm and a thermal conductivity of at least 300 W / mK; Equipped with The insulating layer is made of mica, aerogel, woven mesh, silicone resin, glass fiber, carbon fiber, mineral wool, gypsum board, concrete, titanium, nickel alloy, or a combination thereof. Composite goods.

9. the insulating layer comprises a fire-resistant material; 9. The composite article of claim 8.

10. The insulating layer includes at least one of inorganic fibers, non-metallic fibers, or a combination thereof.

10. A composite article according to claim 8 or 9.

11. a second insulating layer disposed adjacent to the flexible graphite layer, the flexible graphite layer forming a core of the composite article. A composite article according to any one of claims 8 to 10.

12. the second insulating layer comprises at least one of talc, mica, aerogel, woven mesh, silicone resin, glass fiber, carbon fiber, ceramic fiber, ceramic wool, mineral wool, gypsum board, concrete, titanium, nickel alloy, or a combination thereof; 12. The composite article of any one of claims 11.

13. the second insulating layer comprises a fire-resistant material; 13. A composite article according to claim 11 or 12.

14. the second insulating layer comprises at least one of inorganic fibers, non-metallic fibers, or a combination thereof; A composite article according to any one of claims 11 to 13.

15. Comprising an article or composite article according to any one of claims 1 to 14. Shielding articles.

16. further comprising a metal backing layer; The shielding article of claim 15.

17. Further provided with an electrical insulating layer as the outermost layer.

17. The shielding article according to claim 15 or 16.

18. the electrically insulating layer comprises polyimide; 18. The shielding article of claim 17.

19. a. a battery housing having two or more sides; b. a plurality of battery cells disposed within the battery housing; c. the article or composite article of any one of claims 1-15 in contact with at least one of two or more surfaces of the battery housing; Equipped with The article or composite article is disposed on one of the inside and outside surfaces of the battery housing. Battery pack.

20. further comprising a second article and / or a second composite article disposed between two adjacent battery cells; 20. The battery pack of claim 19.

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