Battery assembly busbars

Abstract

A bus bar is provided that includes an insulating portion covering at least a portion of a conductive main portion. The insulating portion includes a polymer composition that includes a polymer matrix containing a thermotropic liquid crystalline polymer. The polymer composition is further configured to be resistant to a shear rate of 1,000 s -1 and a melt viscosity of about 300 Pa·s or less, as measured in accordance with ISO 11443:2021, at a temperature about 15°C above the melting temperature of the composition, and a deflection temperature under load of about 170°C or more, as measured at a load of 1.8 MPa, as measured in accordance with ISO 75:2013.

Description

[Technical Field]

[0001] Related Applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 391,338, filed July 22, 2022, which is incorporated herein by reference. [Background technology]

[0002]

[0001] Electric vehicles, such as battery electric vehicles, plug-in hybrid electric vehicles, mild hybrid electric vehicles, or full hybrid electric vehicles, generally have an electric powertrain that includes an electric propulsion source (e.g., a battery) and a transmission. In electric vehicles, plastic insulating materials are often used to insulate busbars used to connect individual battery cells within a battery. However, one problem is that many conventional materials lack the heat resistance required for use in high-voltage applications. Furthermore, attempts to use high-performance polymers result in other problems, such as low mechanical strength. Therefore, there is currently a need for busbars, such as those used in electric vehicles, that include insulating portions that have a combination of good insulating properties, heat resistance, and mechanical strength. Summary of the Invention [Means for solving the problem]

[0003] According to one embodiment of the present invention, a bus bar is disclosed that includes an insulating portion covering at least a portion of a conductive main portion. The insulating portion includes a polymer composition that includes a polymer matrix containing a thermotropic liquid crystal polymer. Furthermore, the polymer composition is resistant to a shear rate of 1,000 s -1 and a melt viscosity of about 300 Pa·s or less, as measured in accordance with ISO 11443:2021, at a temperature about 15°C above the melting temperature of the composition, and a deflection temperature under load of about 170°C or more, as measured at a load of 1.8 MPa, as measured in accordance with ISO 75:2013.

[0004]

[0003] Other features and aspects of the present invention are described in more detail below.

[0004] A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 1 illustrates one embodiment of a busbar that may be formed in accordance with the present invention. [Figure 2]

[0006] FIG. 10 illustrates another embodiment of a busbar that may be formed in accordance with the present invention. [Figure 3]

[0007] 1 illustrates a portion of a busbar that may be formed in accordance with the present invention, including a cutaway view of the insulating coating. [Figure 4]

[0008] 1 illustrates an end view of one embodiment of a busbar that may be formed in accordance with the present invention. [Figure 5]

[0009] 1 illustrates one embodiment of an electric vehicle in which the high voltage electrical components of the present invention may be used. [Figure 6]

[0010] FIG. 1 illustrates a battery assembly in which the high voltage electrical components of the present invention may be used. [Figure 7]

[0011] 1A and 1B are two perspective views of a bus bar with multiple battery cells arranged thereon that may be used in the present invention. [Figure 8]

[0012] 8 shows the busbar of FIG. 7 fitted to a battery assembly including a housing that may be used in the present invention. [Figure 9]

[0013] FIG. 10 is a diagram showing another embodiment of a bus bar with multiple battery cells arranged thereon that can be used in the present invention. [Figure 10]

[0014] FIG. 10 shows another embodiment of a battery assembly that can be used in the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0006]

[0015] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.

[0016] Those skilled in the art will appreciate that this discussion is a description of exemplary embodiments only and is not intended to limit the broader aspects of the invention.

[0007]

[0017] Generally speaking, the present invention relates to a busbar that can be used in a battery assembly of an electric vehicle, such as a battery-powered electric vehicle, a fuel cell-powered electric vehicle, a plug-in hybrid electric vehicle (PHEV), a mild hybrid electric vehicle (MHEV), or a full hybrid electric vehicle (FHEV). The busbar generally includes an insulating portion covering at least a portion of a conductive main portion (e.g., metal). In particular, the insulating portion contains a polymer composition including a liquid crystal polymer, which exhibits a combination of high flow properties and good heat resistance. More specifically, the composition exhibits a shear rate of 1,000 s -1and at a temperature about 15°C above the melting temperature of the composition (e.g., about 350°C), the composition may exhibit a melt viscosity of about 300 Pa·s or less, in some embodiments about 150 Pa·s or less, in some embodiments about 5 to 100 Pa·s, in some embodiments about 10 to about 95 Pa·s, and in some embodiments about 15 to about 80 Pa·s, as measured in accordance with ISO 11443:2021. The deflection temperature under load ("DTUL"), a measure of short-term heat resistance, may also remain relatively high. For example, the DTUL may be about 170°C or more, in some embodiments about 200°C or more, in some embodiments about 210°C to about 300°C, and in some embodiments about 220°C to about 280°C, as measured at a load of 1.8 MPa, for example, in accordance with ISO 75:2013. Even at such DTUL values, the ratio of melting temperature to DTUL value may still remain relatively high. For example, this ratio may range from about 0.5 to about 1.00, in some embodiments from about 0.6 to about 0.95, and in some embodiments, from about 0.65 to about 0.85. The specific melting temperature of the polymer composition may be, for example, from about 250°C to about 440°C, in some embodiments, from about 260°C to about 400°C, and in some embodiments, from about 300°C to about 380°C.

[0008]

[0018] In addition to exhibiting good flow characteristics and heat resistance, the polymeric composition may exhibit high thermal conductivity. Such high thermal conductivity values enable the composition to form a thermal path for heat transfer from the conductive elements of the busbar. In this way, "hot spots" are quickly eliminated, reducing overall temperatures during use. The polymeric composition may, for example, exhibit an in-plane (or "flow") thermal conductivity of about 2 W / m·K or greater, in some embodiments, from about 2.5 to about 15 W / m·K, in some embodiments, from about 3 to about 10 W / m·K, and in some embodiments, from about 4 to about 8 W / m·K, as measured in accordance with ASTM E 1461-13(2022). Similarly, the polymeric composition may exhibit a cross-plane (or "cross-flow") thermal conductivity of about 0.8 W / m·K or greater, in some embodiments, from about 1 to about 12 W / m·K, and in some embodiments, from about 2 to about 8 W / m·K, as measured in accordance with ASTM E 1461-13(2022). The composition may also exhibit a through plain thermal conductivity of about 0.2 W / m·K or greater, and in some embodiments about 0.3 W / m·K or greater, and in some embodiments, from about 0.5 to about 4 W / m·K, and in some embodiments, from about 0.6 to about 2 W / m·K, as measured in accordance with ASTM E 1461-13(2022).

[0009]

[0019] While being thermally conductive, the polymeric compositions are electrically insulating and can maintain high short-term dielectric strength when exposed to an electric field. "Dielectric strength" generally refers to the voltage a material can withstand before breaking down. For example, the polymeric compositions can generally exhibit a dielectric strength of about 10 kilovolts per millimeter (kV / mm) or greater, in some embodiments about 15 kV / mm or greater, and in some embodiments, about 25 kV / mm to about 60 kV / mm, as measured, for example, according to IEC 60234-1:2013. The insulating properties of the polymeric compositions can also be characterized by a high comparative tracking index ("CTI"), such as about 150 volts or greater, in some embodiments about 170 volts or greater, in some embodiments about 200 volts or greater, and in some embodiments, about 220 to about 350 volts, as measured, for example, according to IEC 60112:2003, at a thickness of 3 millimeters.

[0010]

[0020] Despite possessing the above-described properties, the polymer composition can maintain high strength, thereby providing improved flexibility and impact resistance. The polymer composition can exhibit, for example, a tensile stress at break (i.e., strength) of about 40 MPa to about 300 MPa, in some embodiments about 50 MPa to about 250 MPa, and in some embodiments about 70 to about 200 MPa; a tensile strain at break (i.e., elongation) of about 0.5% or greater, in some embodiments about 1% to about 8%, and in some embodiments about 2% to about 5%; and / or a tensile modulus of about 5,000 to about 30,000 MPa, in some embodiments about 6,000 MPa to about 25,000 MPa, and in some embodiments about 9,000 MPa to about 22,000 MPa. Tensile properties can be determined at a temperature of 23°C according to ISO 527:2019. The composition may also exhibit a flexural strength of about 20 MPa or greater, in some embodiments from about 50 to about 300 MPa, in some embodiments from about 70 to about 250 MPa, and in some embodiments from about 80 to about 200 MPa; and / or a flexural modulus of about 10,000 MPa or less, in some embodiments from about 5,000 MPa to about 30,000 MPa, in some embodiments from about 8,000 MPa to about 25,000 MPa, and in some embodiments from about 9,000 MPa to about 20,000 MPa. Flexural properties may be determined at a temperature of 23°C according to ISO 178:2019. The polymer composition may also exhibit high impact strength, which may impart improved flexibility to the resulting part. For example, the polymer composition may exhibit a flexural modulus of about 2 kJ / m as measured at 23°C according to ISO 179-1:2010. 2 In some embodiments, about 4 to about 20 kJ / m 2 and in some embodiments, from about 6 to about 18 kJ / m 2 Unnotched Charpy impact strength of approximately 10 kJ / m 2 In some embodiments, about 15 to about 50 kJ / m 2 and in some embodiments, from about 20 to about 40 kJ / m 2 The Charpy notched impact strength may be

[0011]

[0021] The polymeric compositions can achieve the characteristic combination of properties described above even at relatively small thicknesses, such as about 8 millimeters or less, in some embodiments about 4 millimeters or less, in some embodiments about 0.2 to about 3.2 millimeters or less, in some embodiments about 0.4 to about 1.6 millimeters, and in some embodiments about 0.4 to about 0.8 millimeters.

[0012]

[0022] Various aspects of the invention will now be described in more detail. I. Polymer Composition A. Polymer matrix

[0023] As described above, the polymer matrix contains at least one liquid crystal polymer. For example, the liquid crystal polymer typically constitutes about 50% to 100% by weight of the polymer matrix, in some embodiments about 70% to 100% by weight, and in some embodiments about 90% to 100% by weight (e.g., 100% by weight). Liquid crystal polymers are generally classified as "thermotropic" as long as they have a rod-like structure and exhibit crystalline behavior in the molten state (e.g., a thermotropic nematic state). Such polymers typically have a DTUL value of about 200°C to about 340°C, in some embodiments about 210°C to about 300°C, and in some embodiments about 220°C to about 280°C, measured at a load of 1.8 MPa according to ISO 75-2:2013. The polymer may also have a relatively high melting temperature, such as about 250°C to about 440°C, in some embodiments about 260°C to about 400°C, and in some embodiments about 300°C to about 380°C. The polymer may be formed from one or more repeat units, as is known in the art. The liquid crystal polymer may, for example, contain one or more aromatic ester repeat units, generally represented by formula (I):

[0013] [ka]

[0014] (In the formula, Ring B is a substituted or unsubstituted 6-membered aryl group (e.g., 1,4-phenylene or 1,3-phenylene), a substituted or unsubstituted 6-membered aryl group fused with a substituted or unsubstituted 5- or 6-membered aryl group (e.g., 2,6-naphthalene), or a substituted or unsubstituted 6-membered aryl group bonded to a substituted or unsubstituted 5- or 6-membered aryl group (e.g., 4,4-biphenylene); Y1 and Y2 are independently O, C(O), NH, C(O)HN, or NHC(O).

[0024] Typically, at least one of Y1 and Y2 is C(O). Examples of such aromatic ester repeat units include, for example, aromatic dicarboxylic acid repeat units (in Formula I, Y1 and Y2 are C(O)), aromatic hydroxycarboxylic acid repeat units (in Formula I, Y1 is O and Y2 is C(O)), and various combinations thereof.

[0015]

[0025] The aromatic hydroxycarboxylic acid repeating unit may be, for example, derived from an aromatic hydroxycarboxylic acid such as 4-hydroxybenzoic acid, 4-hydroxy-4'-biphenylcarboxylic acid, 2-hydroxy-6-naphthoic acid, 2-hydroxy-5-naphthoic acid, 3-hydroxy-2-naphthoic acid, 2-hydroxy-3-naphthoic acid, 4'-hydroxyphenyl-4-benzoic acid, 3'-hydroxyphenyl-4-benzoic acid, 4'-hydroxyphenyl-3-benzoic acid, etc., as well as alkyl, alkoxy, aryl, and halogen substituents thereof, and combinations thereof. Particularly suitable aromatic hydroxycarboxylic acids are 4-hydroxybenzoic acid ("HBA") and 6-hydroxy-2-naphthoic acid ("HNA"). When used, repeat units derived from hydroxycarboxylic acids (e.g., HBA and / or HNA) typically comprise from about 20 mol % to about 80 mol %, in some embodiments from about 25 mol % to about 75 mol %, and in some embodiments, from about 30 mol % to about 70 mol % of the polymer.

[0016]

[0026] The aromatic dicarboxylic acid repeating unit may also be derived from an aromatic dicarboxylic acid, such as terephthalic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid, diphenyl ether-4,4'-dicarboxylic acid, 1,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, 4,4'-dicarboxybiphenyl, bis(4-carboxyphenyl)ether, bis(4-carboxyphenyl)butane, bis(4-carboxyphenyl)ethane, bis(3-carboxyphenyl)ether, bis(3-carboxyphenyl)ethane, etc., as well as alkyl, alkoxy, aryl, and halogen substituents thereof, and combinations thereof. Particularly suitable aromatic dicarboxylic acids include, for example, terephthalic acid ("TA"), isophthalic acid ("IA"), and 2,6-naphthalenedicarboxylic acid ("NDA"). When used, repeat units derived from aromatic dicarboxylic acids (e.g., IA, TA, and / or NDA) typically comprise from about 1 mol % to about 50 mol %, in some embodiments from about 5 mol % to about 40 mol %, and in some embodiments, from about 10 mol % to about 35 mol % of the polymer.

[0017]

[0027] Other repeating units may also be used in the polymer. In certain embodiments, repeating units derived from aromatic diols, such as hydroquinone, resorcinol, 2,6-dihydroxynaphthalene, 2,7-dihydroxynaphthalene, 1,6-dihydroxynaphthalene, 4,4'-dihydroxybiphenyl (or 4,4'-biphenol), 3,3'-dihydroxybiphenyl, 3,4'-dihydroxybiphenyl, 4,4'-dihydroxybiphenyl ether, bis(4-hydroxyphenyl)ethane, and the like, as well as alkyl, alkoxy, aryl, and halogen substituents thereof, and combinations thereof, may be used. Particularly suitable aromatic diols include, for example, hydroquinone ("HQ") and 4,4'-biphenol ("BP"). When used, repeating units derived from aromatic diols (e.g., HQ and / or BP) typically comprise from about 1 mol% to about 40 mol%, in some embodiments, from about 2 mol% to about 35 mol%, and in some embodiments, from about 5 mol% to about 30 mol% of the polymer. Repeat units derived from aromatic amides (e.g., acetaminophen (“APAP”)) and / or aromatic amines (e.g., 4-aminophenol (“AP”), 3-aminophenol, 1,4-phenylenediamine, 1,3-phenylenediamine, etc.) may also be used. When used, repeat units derived from aromatic amides (e.g., APAP) and / or aromatic amines (e.g., AP) typically comprise from about 0.1 mol % to about 20 mol %, in some embodiments from about 0.5 mol % to about 15 mol %, and in some embodiments, from about 1 mol % to about 10 mol % of the polymer. It should also be understood that various other monomeric repeat units may be incorporated into the polymer. For example, in certain embodiments, the polymer may contain one or more repeat units derived from non-aromatic monomers such as aliphatic or alicyclic hydroxycarboxylic acids, dicarboxylic acids, diols, amides, amines, and the like.Of course, in other embodiments, the polymer may be "fully aromatic," in that it has no repeat units derived from non-aromatic (eg, aliphatic or alicyclic) monomers.

[0018]

[0028] Although not required, the liquid crystal polymer may be a "high naphthenic" polymer in that it contains a relatively high content of repeat units derived from naphthenic hydroxycarboxylic acids and naphthenic dicarboxylic acids, such as NDA, HNA, or a combination thereof. That is, the total amount of repeat units derived from naphthenic hydroxycarboxylic acids and / or dicarboxylic acids (e.g., NDA, HNA, or a combination of HNA and NDA) is typically about 10 mol% or more of the polymer, in some embodiments about 12 mol% or more, in some embodiments about 15 mol% or more, in some embodiments about 15 mol% to about 50 mol%, and in some embodiments, 16 mol% to about 30 mol%. In one embodiment, for example, the repeat units derived from NDA are within the above-mentioned ranges. The liquid crystal polymer may also contain various other monomers. For example, the polymer may contain repeat units derived from HBA in an amount of about 20 mol% to about 60 mol%, in some embodiments about 25 mol% to about 55 mol%, and in some embodiments about 30 mol% to about 50 mol%. The polymer may also contain aromatic dicarboxylic acids (e.g., IA and / or TA) in an amount of about 1 mol % to about 15 mol % and / or aromatic diols (e.g., BP and / or HQ) in an amount of about 10 mol % to about 35 mol %. Of course, in other embodiments, the liquid crystal polymer may be a "low naphthenic" polymer in that it contains a relatively low content of repeat units derived from naphthenic hydroxycarboxylic acids and naphthenic dicarboxylic acids, such as naphthalene-2,6-dicarboxylic acid ("NDA"), 6-hydroxy-2-naphthoic acid ("HNA"), or combinations thereof. That is, the total amount of repeat units derived from naphthenic hydroxycarboxylic acids and / or dicarboxylic acids (e.g., NDA, HNA, or combinations of HNA and NDA) may be about 10 mol % or less of the polymer, in some embodiments about 8 mol % or less, and in some embodiments, from about 1 mol % to about 6 mol %.

[0019]

[0029] In many cases, it is desirable for a significant portion of the polymer matrix to be formed from such high naphthenic polymers. For example, the high naphthenic polymers described herein typically constitute 50% or more by weight of the polymer matrix, in some embodiments, about 65% or more by weight, in some embodiments, about 70% to 100% by weight, and in some embodiments, about 80% to 100% by weight (e.g., 100% by weight). In some cases, blends of polymers may be used. For example, the low naphthenic liquid crystalline polymer may constitute about 1% to about 50% by weight, in some embodiments, about 2% to about 40% by weight, and in some embodiments, about 5% to about 30% by weight of the total amount of liquid crystalline polymer in the composition, and the high naphthenic liquid crystalline polymer may constitute about 50% to about 99% by weight, in some embodiments, about 60% to about 98% by weight, and in some embodiments, about 70% to about 95% by weight of the total amount of liquid crystalline polymer in the composition. B. Optional Additives

[0030] In certain embodiments, the polymer composition may be formed entirely from a polymer matrix (i.e., 100% by weight). Of course, in other embodiments, one or more additives may be dispersed throughout the polymer matrix to help provide desired properties. When used, such additives typically comprise from about 0.1 to about 300 parts by weight, in some embodiments from about 0.5 to about 250 parts by weight, and in some embodiments, from about 1 to about 200 parts by weight, per 100 parts by weight of the polymer matrix. The additive may, for example, comprise from about 0.1% to about 80% by weight, in some embodiments from about 0.5% to about 70% by weight, and in some embodiments, from about 1% to about 60% by weight of the polymer composition.

[0020]

[0031] In one particular embodiment, for example, the polymer composition may contain a thermally conductive filler dispersed within the polymer matrix. To help achieve the desired balance between thermal conductivity, high flowability, and good mechanical properties, the relative amount of the thermally conductive filler is typically adjusted to range from about 10 to about 250 parts by weight, in some embodiments from about 40 to about 250 parts by weight, in some embodiments from about 60 to about 200 parts by weight, and in some embodiments from about 80 to about 190 parts by weight, per 100 parts by weight of the polymer matrix. The thermally conductive filler may comprise, for example, from about 20 to about 70% by weight, in some embodiments from about 28 to about 62% by weight, in some embodiments from about 35 to about 65% by weight, and in some embodiments from about 40 to about 60% by weight of the polymer composition.

[0021]

[0032] Optionally, the thermally conductive filler may include a material with a high intrinsic thermal conductivity. For example, the polymer composition may contain a material with an intrinsic thermal conductivity of 50 W / m·K or greater, in some embodiments, 100 W / m·K or greater, and in some embodiments, 150 W / m·K or greater. Examples of such materials with a high intrinsic thermal conductivity include boron nitride, aluminum nitride, magnesium silicon nitride, graphite (e.g., expanded graphite), silicon carbide, carbon nanotubes, zinc oxide, magnesium oxide, beryllium oxide, zirconium oxide, yttrium oxide, aluminum powder, and copper powder. While such materials may be used in certain embodiments, it has been discovered that high thermal conductivity can be achieved without using traditional materials with high intrinsic thermal conductivity. For example, the polymer composition may generally be free of fillers with high intrinsic thermal conductivity. That is, such fillers may comprise about 10 wt % or less, in some embodiments about 5 wt % or less, and in some embodiments, 0 wt % to about 2 wt % (e.g., 0 wt %) of the polymer composition.

[0022]

[0033] In one particular embodiment, for example, the thermally conductive filler may contain mineral particles. When used, such mineral particles typically comprise about 70 to about 250 parts by weight, in some embodiments about 75 to about 200 parts by weight, and in some embodiments about 90 to about 190 parts by weight, per 100 parts by weight of the polymer matrix. The mineral particles may comprise, for example, about 30% to about 70% by weight, in some embodiments about 35% to about 65% by weight, and in some embodiments about 40% to about 60% by weight of the polymer composition. The mineral particles may be formed from natural and / or synthetic silicate minerals, such as talc, mica, halloysite, kaolinite, illite, montmorillonite, vermiculite, palygorskite, pyrophyllite, calcium silicate, aluminum silicate, and wollastonite. Talc is particularly suitable for use in the polymer composition. The shape of the particles may vary as desired, such as granular or flaky. The particles typically have a median particle size (D50) of about 1 to about 25 micrometers, in some embodiments about 2 to about 15 micrometers, and in some embodiments about 4 to about 10 micrometers, as measured by sedimentation analysis (e.g., Sedigraph 5120). If desired, the particles also have a median particle size (D50) of about 1 square meter per gram (m 2 / g) ~ approx. 50m 2 / g, in some embodiments, about 1.5 m 2 / g ~ approx. 25m 2 / g, in some embodiments, about 2m 2 / g ~ approx. 15m 2 The specific surface area may be high, such as 1 / g. The surface area may be determined by the physical gas adsorption (BET) method according to DIN 66131:1993 (the adsorbed gas is nitrogen). The moisture content may also be relatively low, such as about 5% or less, in some embodiments about 3% or less, and in some embodiments, about 0.1 to about 1%, as determined according to ISO 787-2:1981 at a temperature of 105°C.

[0023]

[0034] In addition to and / or instead of mineral particles, the thermally conductive filler may also contain mineral fibers (also known as "whiskers"). When used, such mineral fibers typically comprise from about 10 to about 150 parts by weight, in some embodiments from about 15 to about 100 parts by weight, and in some embodiments, from about 20 to about 80 parts by weight, based on 100 parts by weight of the polymer matrix. The mineral fibers may, for example, comprise from about 10% to about 50% by weight, in some embodiments, from about 15% to about 45% by weight, and in some embodiments, from about 20% to about 40% by weight of the polymer composition. Examples of such mineral fibers include those derived from silicates, such as neosilicates, sorosilicates, inosilicates (e.g., calcium inosilicates such as wollastonite; calcium magnesium inosilicates such as tremolite; calcium magnesium iron inosilicates such as actinolite; magnesium iron inosilicates such as anthophyllite; etc.), phyllosilicates (e.g., aluminum phyllosilicates such as palygorskite), tectosilicates, etc.; sulfates, such as calcium sulfate (e.g., dehydrated gypsum or anhydrous gypsum); mineral wool (e.g., rock or slag wool); etc. Particularly suitable are inosilicates, such as wollastonite fibers available from Nyco Minerals under the trade name NYGLOS® (e.g., NYGLOS® 4W or NYGLOS® 8). The mineral fibers may have a median diameter of about 1 to about 35 micrometers, in some embodiments about 2 to about 20 micrometers, in some embodiments about 3 to about 15 micrometers, and in some embodiments about 7 to about 12 micrometers. The mineral fibers may also have a narrow size distribution. That is, at least about 60% by volume of the fibers, in some embodiments at least about 70% by volume of the fibers, and in some embodiments at least about 80% by volume of the fibers may have a size within the above range.In addition to possessing the above-described size characteristics, the mineral fibers may have a relatively high aspect ratio (average length divided by median diameter), which helps further enhance the mechanical properties and surface quality of the resulting polymer composition. For example, the mineral fibers may have an aspect ratio of from about 2 to about 100, in some embodiments from about 2 to about 50, in some embodiments from about 3 to about 20, and in some embodiments from about 4 to about 15. The volume average length of such mineral fibers may range, for example, from about 1 to about 200 micrometers, in some embodiments from about 2 to about 150 micrometers, in some embodiments from about 5 to about 100 micrometers, and in some embodiments from about 10 to about 50 micrometers.

[0024]

[0035] The polymer composition may also contain various other optional ingredients to help improve its overall properties. For example, the polymer composition may contain a metal hydroxide, which can effectively "lose" hydroxide ions during processing with the polymer, initiating chain scission of the polymer, reducing its molecular weight and reducing the polymer's melt viscosity under shear. When used, the metal hydroxide may comprise from about 0.05 to about 10 parts by weight, in some embodiments from about 0.1 to about 5 parts by weight, and in some embodiments, from about 0.2 to about 3 parts by weight, based on 100 parts by weight of the polymer matrix. For example, the metal hydroxide may comprise from about 0.01% to about 5% by weight, in some embodiments from about 0.05% to about 4% by weight, and in some embodiments, from about 0.1% to about 2% by weight of the polymer composition.

[0025]

[0036] An example of a suitable metal hydroxide is one having the general formula M(OH) swhere s is an oxidation state (typically 1-3) and M is a metal such as a transition metal, alkali metal, alkaline earth metal, or main group metal. Examples of suitable metal hydroxides include copper(II) hydroxide (Cu(OH)2), potassium hydroxide (KOH), sodium hydroxide (NaOH), magnesium hydroxide (Mg(OH)2), calcium hydroxide (Ca(OH)2), aluminum hydroxide (Al(OH)3), and the like. Also suitable are metal alkoxide compounds capable of forming hydroxyl functional groups in the presence of a solvent such as water. Such compounds have the general formula M(OR) s where s is an oxidation state (usually 1-3), M is a metal, and R is an alkyl. Examples of such metal alkoxides include copper(II) ethoxide (Cu 2+ (CH3CH2O - )2), potassium ethoxide (K + (CH3CH2O - )), sodium ethoxide (Na + (CH3CH2O - )), magnesium ethoxide (Mg 2+ (CH3CH2O - )2), calcium ethoxide (Ca 2+ (CH3CH2O - ) 2) etc.; aluminum ethoxide (Al 3+ (CH3CH2O - In certain embodiments, the metal hydroxide can be in the form of metal hydroxide particles. For example, the particles can have the general formula: Al(OH) a O bwhere 0≦a≦3 (e.g., 1), b=(3−a) / 2. In one particular embodiment, for example, the particles exhibit a boehmite crystalline phase, and the aluminum hydroxide has the formula AlO(OH) ("aluminum oxide hydroxide"). The metal hydroxide particles can be acicular, ellipsoidal, plate-like, spherical, or the like. In any case, the particles typically have a median particle size (D50) of about 50 to about 800 nanometers, in some embodiments about 150 to about 700 nanometers, and in some embodiments about 250 to about 500 nanometers, as measured by non-invasive backscattering (NIBS) techniques. If desired, the particles can also have a surface area of about 2 square meters per gram (m 2 / g) ~ approx. 100m 2 / g, in some embodiments, about 5m 2 / g~about 50m 2 / g, in some embodiments, about 10 m 2 / g ~ approx. 30m 2 The surface area may be determined by the physical gas adsorption (BET) method (adsorbed gas is nitrogen) in accordance with ISO 9277:2010. The moisture content may also be relatively low, such as about 5% or less, in some embodiments about 3% or less, and in some embodiments, about 0.1 to about 1%, as determined in accordance with ISO 787-2:1981.

[0026]

[0037] Further components that may be included in the composition include, for example, reinforcing fibers (e.g., glass fibers), pigments (e.g., black pigments), antioxidants, stabilizers, crosslinkers, lubricants, impact modifiers, flow promoters, and other materials added to improve properties and processability. II. Melt Processing

[0038] Methods for combining the liquid crystalline polymer with various other optional additives (e.g., thermally conductive fillers, pigments, lubricants, etc.) may vary as known in the art. For example, materials may be fed simultaneously or sequentially into a melt-processing device that dispersively mixes the materials. Batch and / or continuous melt-processing techniques may be used. For example, mixers / kneaders, Banbury mixers, Farrel continuous mixers, single-screw extruders, twin-screw extruders, roll mills, etc. may be utilized to mix and melt-process the materials. A particularly suitable melt-processing device is a co-rotating twin-screw extruder (e.g., a Leistritz co-rotating fully intermeshing twin-screw extruder). Such extruders are equipped with feed ports and exhaust ports to provide intensive distributive and dispersive mixing. For example, components may be fed into the same or different feed ports of a twin-screw extruder and melt-mixed to form a substantially homogeneous molten mixture. Melt-mixing may be performed at high shear / pressure and elevated temperatures to ensure adequate dispersion. For example, melt processing can be carried out at a temperature of about 150° C. to about 450° C., and in some embodiments, about 250° C. to about 400° C. Similarly, the apparent shear rate during melt processing can be about 100 sec -1 ~Approx. 10,000sec -1 , in some embodiments, about 500 seconds -1 ~Approx. 1,500sec -1 Of course, other variables such as residence time during melt processing (which is inversely proportional to the throughput rate) can also be controlled to achieve the desired degree of homogeneity.

[0027]

[0039] Optionally, one or more distributive and / or dispersive mixing elements can be used in the mixing section of the melt processing unit. Suitable distributive mixers include, for example, Saxon, Dulmage, and cavity transfer mixers. Similarly, suitable dispersive mixers include Blister ring, Leroy / Maddock, and CRD mixers. As is well known in the art, the intensity of mixing can be further enhanced by using pins in the barrel to fold and reorient the polymer melt, such as those used in Buss Kneader extruders, cavity transfer mixers, and vortex intermeshing pin mixers. Additionally, the screw speed can be controlled to improve the properties of the composition. For example, in one embodiment, the screw speed can be about 400 rpm or less, e.g., about 200 rpm to about 350 rpm, or about 225 rpm to about 325 rpm. In one embodiment, compounding conditions can be balanced to result in a polymer composition exhibiting improved properties. For example, compounding conditions can include screw designs that result in mild, medium, or aggressive screw conditions. For example, a system can have a mildly aggressive screw design with a single melting section in the downstream half of the screw for gentle melting and homogenization of the distributed melt. A medium-aggressive screw design can have a more aggressive melting section upstream of the filler supply barrel, emphasizing more aggressive dispersing elements to achieve uniform melting. In addition, the design can have another gentle mixing section downstream to mix the filler. This section, while weaker, can increase the shear strength of the screw, making it stronger overall than a mildly aggressive design. A very aggressive screw design can have the greatest shear strength of the three designs.The main melting section can consist of a long array of kneading blocks with a high degree of dispersion. The downstream mixing section can utilize a combination of distributive and centralized dispersion elements to achieve uniform dispersion of all types of fillers. The shear strength of the very aggressive screw design can be significantly higher than the other two designs. In one embodiment, the system can include a medium-to-aggressive screw design with a relatively mild screw speed (e.g., about 200 rpm to about 300 rpm).

[0028] III. Busbar

[0040] A variety of different busbar configurations can be formed using the polymer compositions described herein. For example, the busbar can be used in a battery assembly containing a first battery having a first terminal (e.g., a positive terminal) and a second battery having a second terminal (e.g., a positive terminal or a negative terminal). The first and second terminals of the batteries can be connected to each other by a busbar including a conductive main portion and an insulating portion. The insulating portion can be formed from the polymer composition of the present invention.

[0029]

[0041] Referring to FIG. 1 , one embodiment of a busbar 10 is shown, including a conductive main portion 12. The main portion 12 comprises a conductive material 18, such as copper, aluminum, an aluminum alloy, or the like, and may generally be in the form of a solid rod, a hollow tube, or the like. The busbar 10 includes connector portions 14 at both ends configured to mate with respective terminations of two or more batteries. An insulating portion 16 (e.g., a coating or molding compound) comprising a polymer composition described herein may cover a portion of the conductive material of the main portion 12. To form the busbar 10, the insulating portion 16 may be applied to the surface of the conductive material 18. For example, a rod or tube of the conductive material 18 may be inserted into a preformed tube of insulating coating 16, such as an extruded tube sized and cut to the appropriate proportions, and the busbar 10 may then be molded into any suitable shape. In another embodiment, the insulating coating may be applied to the surface of the conductive material 18 in a molten state and allowed to solidify on the surface of the conductive material in the applied area.

[0030]

[0042] 2 shows another example of a busbar 20 that may include an insulating portion in the form of a coating disposed on a conductive body. In this embodiment, the busbar 20 includes a tubular conductive body covered along its length with an insulating coating 26, which may include a polymer composition as described. The busbar 20 may also include connector portions 24 at each end that are configured to connect to the power receiving terminals of a battery.

[0031]

[0043] 3-4 show a portion of a busbar 30 that may include a high-surface-area insulating portion. More specifically, the insulating portion 36 is disposed on a corrugated, tubular conductive main portion 38 having alternating peaks 31 and valleys 32. The insulating portion 36 may contain the polymer composition of the present invention. Optionally, the valleys 32 may have an inner diameter slightly larger than the outer diameter of the conductive main portion 38, while the peaks 31 may have a space 33 between the conductive main portion 38 and the wall of the peak 31. In one embodiment, the peaks 31 may include vent holes 34 at specific locations. The busbar 30 also includes a terminal 33 at the end of the conductive main portion 38, which includes a plate 33a and an opening 33b for mating with a battery. In one embodiment, the insulating portion 36 includes a notch 39 extending axially along its entire length and may be openable and closable circumferentially. The conductive main portion 38 can then be inserted into the open insulating portion 36. Optionally, heat-resistant tape 35 may be wrapped around the end of conductive main portion 38 to prevent displacement of conductive main portion 38 within insulating portion 36 .

[0032]

[0044] The insulating portion of the busbar can be formed from the polymer composition using a variety of different techniques. Suitable techniques include, for example, injection molding, low-pressure injection molding, extrusion compression molding, gas injection molding, foam injection molding, low-pressure gas injection molding, low-pressure foam injection molding, gas extrusion compression molding, foam extrusion compression molding, extrusion molding, foam extrusion molding, compression molding, foam compression molding, and gas compression molding. For example, an injection molding system can be used, including a mold into which the polymer composition can be injected. The time in the injector can be controlled and optimized to prevent pre-solidification of the polymer matrix. Once the cycle time is reached and the barrel is full for discharge, a piston can be used to inject the composition into the mold cavity. Compression molding systems can also be used. Similar to injection molding, the polymer composition can also be molded into the desired article in a mold. The composition can be placed into the compression mold using any known technique, such as by being picked up by an automated robotic arm. The temperature of the mold can be maintained at or above the solidification temperature of the polymer composition for a desired time to allow solidification. The molded article can then be solidified by lowering the temperature below the melting temperature. The resulting product may be demolded. The cycle time of each molding process may be tailored to the polymer composition to achieve sufficient bonding and increase overall process productivity.

[0033]

[0045] As previously mentioned, busbars are particularly beneficial for use in electric vehicles. For example, referring to FIG. 5 , one embodiment of an electric vehicle 112 is shown including a powertrain 110. The powertrain 110 contains one or more electric machines 114 connected to a transmission 116, which is mechanically connected to a drive shaft 120 and wheels 122. Although by no means required, in this particular embodiment, the transmission 116 is also connected to an engine 118. The electric machines 114 may be operable as motors or generators to provide propulsion and retardation. The powertrain 110 also includes a propulsion source, such as a battery assembly 124, which stores and supplies energy used by the electric machines 114. The battery assembly 124 typically provides a high-voltage current output (e.g., direct current at a voltage of about 400 volts to about 800 volts) from one or more battery cell arrays, which may include one or more battery cells.

[0034]

[0046] The powertrain 110 may also contain at least one power electronics module 126 connected to the battery assembly 124 and which may contain power converters (e.g., inverters, rectifiers, voltage converters, etc., and combinations thereof). The power electronics module 126 is typically electrically connected to the electric machine 114 and provides the ability to transfer electrical energy bidirectionally between the battery assembly 124 and the electric machine 114. For example, the battery assembly 124 may provide a DC voltage, while the electric machine 114 may require a three-phase AC voltage to function. The power electronics module 126 can convert the DC voltage to the three-phase AC voltage required by the electric machine 114. In a regenerative mode, the power electronics module 126 can convert the three-phase AC voltage from the electric machine 114, which functions as a generator, to the DC voltage required by the battery assembly 124. The description herein is equally applicable to purely electric vehicles. The battery assembly 124 may also supply energy to other vehicle electrical systems. For example, the powertrain may use a DC / DC converter module 128 to convert high-voltage DC output from the battery assembly 124 into a low-voltage DC power supply compatible with other vehicle loads, such as a compressor or electric heater. In a typical vehicle, the low-voltage system is electrically connected to an auxiliary battery 130 (e.g., a 12V battery). There may also be a battery energy control module (BECM) 133 in communication with the battery assembly 124, which acts as a controller for the battery assembly 124 and may include an electronic monitoring system that manages the temperature and state of charge of each battery cell. The battery assembly 124 may also have a temperature sensor 131, such as a thermistor or other thermometer. The temperature sensor 131 may communicate with the BECM 133 to provide temperature data regarding the battery assembly 124. The temperature sensor 131 may also be located on or near a battery cell within the traction battery 124. It is contemplated that more than one temperature sensor 131 may be used to monitor the temperature of the battery cells.

[0035]

[0047] In certain embodiments, the battery assembly 124 may be recharged by an external power source 136, such as an electrical outlet. The external power source 136 may be electrically connected to an electric vehicle supply equipment (EVSE), which regulates and manages the transfer of electrical energy between the power source 136 and the vehicle 112. The EVSE 138 may have a charging connector 140 for plugging into a charging port 134 of the vehicle 112. The charging port 134 may be any type of port configured to transfer power from the EVSE 138 to the vehicle 112 and may be electrically connected to a charger or an onboard power conversion module 132. The power conversion module 132 may condition the power provided by the EVSE 138 to provide the appropriate voltage and current levels to the battery assembly 124. The power conversion module 132 may interface with the EVSE 138 to regulate the power supply to the vehicle 112.

[0036]

[0048] Referring again to FIG. 5 , bus bars (not shown) may be used to electrically connect the individual cells of the battery assembly 124. Referring to FIG. 6 , for example, the battery assembly 124 may include multiple battery cells 158. The battery cells 158 may be stacked horizontally to form a collection of battery cells, sometimes referred to as a battery array. In one embodiment, the battery cells 158 are prismatic lithium-ion batteries. However, battery cells having other shapes (cylindrical, pouch-shaped, etc.) and / or chemistries (nickel-metal hydride, lead-acid, etc.) may alternatively be utilized within the scope of the present disclosure. Each battery cell 158 includes a positive terminal (designated by a (+) symbol) and a negative terminal (designated by a (-) symbol). The battery cells 158 are arranged such that the terminal of each battery cell 158 is positioned adjacent to the terminal of an adjacent battery cell 158 having the opposite polarity. As used herein, the terms “battery,” “cell,” and “battery cell” may be used interchangeably to refer to any type of individual battery element used in a battery system. The batteries described herein typically include lithium-based batteries, but can also include a variety of chemistries and configurations, including iron phosphate, metal oxide, lithium ion polymer, nickel metal hydride, nickel cadmium, nickel-based batteries (metal hydride, zinc, cadmium, etc.), and any other battery type compatible with electric vehicles. For example, in some embodiments, a Panasonic® 6831 NCR 18650 battery cell or a variation of the 18650 form factor measuring 6.5 cm by 1.8 cm and approximately 45 g can be used.

[0037]

[0049] The manner in which a bus bar connects to individual battery cells, such as those shown in FIG. 6, may vary as known in the art. For example, referring to FIG. 7, a top isometric view 900 and a bottom isometric view 902 illustrate a planar bus bar 906 with multiple battery cells 904 arranged in multiple rows. The multiple battery cells 904 are arranged in sets of adjacent rows, as shown in FIG. 6 above. The cutouts 901 in the bus bar 906 may include recesses that allow individual battery cells 904 to be positioned within portions of the cutouts 901. In these embodiments, the bus bar 906 may be used as a template for uniformly positioning the individual battery cells in each battery assembly produced. The bus bar 906 may also hold the individual battery cells 904 in place during the manufacturing process, allowing any thermal pads or injection housings, which may be formed from the polymer compositions described herein, to be added without displacing the individual battery cells. As shown by diagram 902, the central tab 910 of each cutout can make spring-like contact with the underside of each individual battery terminal without requiring soldering or any other type of mechanical connection. The bus bar 906 can include insulators 912, as described herein, at each contact area / perimeter of each cutout 901 that can hold the end of each battery cell 904. The insulators 912 can, in some embodiments, extend onto the bus bar 906 beyond the cutouts 901.

[0038]

[0050] FIG. 8 shows a bottom isometric view 1002 of a battery assembly having a housing 1004 and a mated bus bar 906. Optionally, the housing 1004 can be formed from a polymer composition described herein. The housing 1004 can be formed by injection into an injection mold to attach to and retain the battery cells 904. In one embodiment, the housing 1004 is attached flush with the top surfaces of the individual battery cells 904. In some embodiments, the housing 1004 does not cover the top or bottom of the individual battery cells 904. Instead, these areas of the individual battery cells 904 are left exposed so that electrical connection can be made between the individual battery cells 904 and the bus bar 906 after the housing is attached. In other embodiments (not shown), the housing 1004 does not extend all the way to the top and / or bottom terminals of the battery assembly. In some embodiments, the exposed portion of the individual battery cells 904 can be between 1.0 mm and 15.0 mm. The amount of exposure of the individual battery cells 904 may vary between the top and bottom of each individual battery cell 904. By exposing a portion of the individual battery cells 904, certain electrical connections to the individual battery cells may be more easily made.

[0039]

[0051] In some embodiments, the bus bar 906 may be disposed within the housing 1004, which may cover the connection between the bus bar and the battery cells 904. In one embodiment, the battery assembly may include a polymer composition described herein injected into the housing 1004 to form a solid-state battery assembly. In some embodiments, the bus bar 916 may be secured to the bottom of the battery assembly by the housing 1004 or by other mechanical means such as screws and / or adhesives.

[0040]

[0052] 7-8 illustrate a plate-type bus bar 906 defined by a continuous plane that contacts all of the batteries within the depicted section of the battery assembly. However, other embodiments need not be so limited. For example, FIG. 8 illustrates another embodiment of the bus bars 914, 916 described herein that may be utilized in a battery assembly. As shown, the battery assembly may include multiple bus bars 914, 916 shaped as individual lengths of conductive bar with insulation covering one or more portions of the bus bar. The bus bars may be of any suitable geometric shape, such as a single straight bus bar 914, or a Z-bus bar 916, or a three-dimensional shape as previously described. For example, a straight bus bar 914 may connect to each battery cell 904 in a single column in the battery assembly, and the Z-bus bar 916 can provide connections from the bus bar 914 to other electrical components of the system (e.g., an inverter). As shown in FIGS. 8-9 , the battery assembly may also include one or more connectors 908, as described above, for electrically connecting the battery assembly to other components of the electric vehicle, such as a power electronics module, such as the power electronics module 126, the DC / DC converter module 128, and / or the power conversion module 132, as shown in FIG. 5 .

[0041]

[0053] FIG. 10 shows another embodiment of a battery assembly that can use the polymer composition of the present invention. As shown, the battery assembly includes a plurality of battery cells 301 arranged in series in the longitudinal direction Y, an end plate 306, a side plate 307, and a wiring harness assembly 308. The battery assembly also includes two electrode terminals, i.e., a positive electrode terminal T1 and a negative electrode terminal T2, protruding outward from the top of the battery assembly. In one embodiment, the end plate 306 and the side plate 307 can be connected together to form a rectangular frame as shown. The battery cells 301 can be fixed to the frame by adhesive bonding. The bus bar assembly includes a plurality of flat bus bars 302, 303, and 305, which are fixed to the wiring harness assembly 308. Optionally, the bus bars 302, 303, and / or 305 can include the polymer composition described herein, for example, as a coating on a portion of the bus bar or as a separator between the bus bar and another component.

[0042]

[0054] The present invention may be better understood with reference to the following examples. [Example]

[0043] Test Method

[0055] thermal conductivity As is known in the art, the thermal diffusivity of a sample in various directions (in-plane, cross-plane, and out-of-plane) can first be determined based on the laser flash method according to ASTM E1461-13(2022). The thermal conductivity (in-plane, cross-plane, and out-of-plane) can then be calculated according to the following formula: Thermal Conductivity (W / m K) = Cp × ρ × α, where Cp is the specific heat capacity of the sample (J / kgK), and ρ is the intrinsic density of the sample (kg / m), determined according to ISO 11831-1:2019 (Method A). 3 ), α is the measured thermal diffusivity (m 2 / s)

[0056] Melt Viscosity The melt viscosity (Pa s) was measured using a Dynisco LCR7001 capillary rheometer at a shear rate of 1,000 s -1 and can be determined in accordance with ISO 11443:2021. The rheometer orifice (die) can have a diameter of 1 mm, a length of 20 mm, an L / D ratio of 20.1, and an inlet angle of 180°. The barrel diameter can be 9.55 mm + 0.005 mm, and the rod length can be 233.4 mm. Melt viscosity is typically determined at a temperature 15°C above the melting temperature of the polymer and / or composition, e.g., about 350°C.

[0044]

[0057] Melting temperature The melting temperature ("Tm") can be determined by differential scanning calorimetry ("DSC"), as known in the art. The melting temperature is the differential scanning calorimetry (DSC) peak melting temperature as determined by ISO test number 11357-3:2018. For the DSC procedure, using DSC measurements performed on a TA Q2000 instrument, the sample was heated and cooled at 20°C per minute, as described in ISO standard 10350.

[0045]

[0058] Tensile modulus, tensile stress at break, and tensile strain at break Tensile properties can be tested according to ISO 527:2019 (technically equivalent to ASTM D638-14). Modulus and strength measurements can be performed on the same test strip sample, measuring 80 mm in length, 10 mm in thickness, and 4 mm in width. The test temperature can be 23°C, and the test speed can be 5 mm / min for tensile strength and tensile strain at break, and 1 mm / min for tensile modulus.

[0046]

[0059] Flexural modulus and flexural stress Flexural properties can be tested according to ISO 178:2019 (technically equivalent to ASTM D790-10). The test can be performed with a support span of 64 mm. The test can be performed on the center section of an uncut ISO 3167 multi-purpose bar. The test temperature can be 23°C, and the test speed can be 2 mm / min.

[0047]

[0060] Charpy impact strength Charpy properties can be tested according to ISO 179-1:2010 (technically equivalent to ASTM D256-10, Method B). The test can be performed using a Type 1 specimen size (80 mm length, 10 mm width, and 4 mm thickness). Specimens can be cut from the center of a general-purpose specimen using a single-tooth milling machine. The test temperature can be 23°C. For notched impact strength, the test can be performed using a Type A notch (0.25 mm base radius) and a Type 1 specimen size (80 mm length, 10 mm width, and 4 mm thickness).

[0048]

[0061] Comparative Tracking Index ("CTI") The comparative tracking index (CTI), determined in accordance with international standard IEC 60112-2003, provides a quantitative indication of a composition's ability to function as an electrical insulator under moist and / or contaminated conditions. To determine a composition's CTI rating, two electrodes are placed on a molded specimen. A voltage difference is then established between the electrodes while a 0.1% aqueous ammonium chloride solution is dripped onto the specimen. The maximum voltage that five specimens can withstand without failure during a 50-drop test is determined. Test voltages range from 100 to 600 V in 25 V increments. The voltage at which failure occurs after 50 drops of electrolyte is the "comparative tracking index." This value is an indication of the material's relative tracking resistance. According to UL 746A, a nominal section thickness of 3 mm is considered representative of performance at other thicknesses.

[0049] Examples 1 and 2

[0062] The following two commercially available samples were compounded and injection molded for use in bus bars:

[0050] [Table 1]

[0051]

[0063] LCP1 is believed to be formed from 73% HBA and 27% HNA. LCP2 is believed to be formed from 50% HBA, 25% BP, and 25% TA. The samples were tested for mechanical properties, thermal properties, and thermal conductivity as described herein. The results are set forth below.

[0052] [Table 2]

[0053] Example 3

[0064] The following samples were compounded and injection molded for use in bus bars:

[0054] [Table 3]

[0055]

[0065] LCP3 is made from 43% HBA, 20% NDA, 9% TA, and 28% HQ. Samples were tested for mechanical properties, thermal properties, and thermal conductivity as described herein. The results are set forth below.

[0056] [Table 4]

[0057]

[0066] These and other modifications and variations of the present invention may be practiced by those skilled in the art without departing from the spirit and scope of the present invention. Moreover, it should be understood that aspects of the various embodiments may be interchanged in whole or in part. Furthermore, those skilled in the art will appreciate that the foregoing description is illustrative only and is not intended to limit the invention as further described in the appended claims.

Claims

1. 1. A bus bar comprising an insulating portion covering at least a portion of a conductive main portion, the insulating portion comprising a polymer composition including a polymer matrix containing a thermotropic liquid crystal polymer, the polymer composition being resistant to a shear rate of 1,000 s －１ and a melt viscosity of about 300 Pa s or less, as measured in accordance with ISO 11443:2021 at a temperature about 15°C above the melting temperature of the composition, and a deflection temperature under load of about 170°C or greater, as measured at 1.8 MPa in accordance with ISO 75:2013.

2. The busbar of claim 1 , wherein the polymer composition exhibits a melting temperature of from about 250° C. to about 440° C.

3. 10. The busbar of claim 1, wherein the thermotropic liquid crystalline polymer contains repeat units derived from one or more aromatic dicarboxylic acids, one or more aromatic hydroxycarboxylic acids, or a combination thereof.

4. 4. The bus bar of claim 3, wherein the aromatic hydroxycarboxylic acid comprises 4-hydroxybenzoic acid, 6-hydroxy-2-naphthoic acid, or a combination thereof.

5. 5. The bus bar of claim 4, wherein the aromatic dicarboxylic acid comprises terephthalic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid, or a combination thereof.

6. 4. The bus bar of claim 3, wherein the liquid crystalline polymer further contains repeat units derived from one or more aromatic diols.

7. The busbar of claim 6, wherein the aromatic diol comprises hydroquinone, 4,4'-biphenol, or a combination thereof.

8. The bus bar of claim 1 , wherein the thermotropic liquid crystalline polymer is wholly aromatic.

9. 10. The bus bar of claim 1, wherein the thermotropic liquid crystalline polymer comprises repeat units derived from naphthenic hydroxycarboxylic acids and / or dicarboxylic acids in an amount of about 10 mol % or greater.

10. 10. The busbar of claim 1, wherein the polymer composition exhibits an in-plane thermal conductivity of greater than or equal to about 2 W / m·K as measured in accordance with ASTM E1461-13(2022).

11. 10. The busbar of claim 1, wherein the polymer composition exhibits a cross-plane thermal conductivity of greater than or equal to about 0.8 W / m·K as measured in accordance with ASTM E1461-13(2022).

12. 10. The busbar of claim 1, wherein the polymer composition exhibits an in-plane thermal conductivity of about 4 to about 8 W / m·K as measured in accordance with ASTM E1461-13(2022).

13. 10. The busbar of claim 1, wherein the polymer composition exhibits a dielectric strength of greater than or equal to about 10 kilovolts per millimeter as measured in accordance with IEC 60234-1:2013.

14. The busbar of claim 1 , wherein the polymer composition further comprises a thermally conductive filler.

15. The busbar of claim 14 , wherein the thermally conductive filler comprises mineral particles.

16. The busbar of claim 15 , wherein the mineral particles comprise talc.

17. 16. The busbar of claim 15, wherein the mineral particles comprise from about 70 to about 250 parts by weight per 100 parts by weight of the polymer matrix.

18. The mineral particles have a median diameter of about 1 to about 25 micrometers, and a median diameter of about 1 to about 50 micrometers as measured in accordance with DIN 66131:1993. ２ / g and / or a moisture content of about 5% or less as measured in accordance with ISO 787-2:1981 at a temperature of 105°C.

19. The busbar of claim 14 , wherein the thermally conductive filler comprises mineral fibers.

20. 20. The busbar of claim 19, wherein the mineral fibers comprise wollastonite.

21. 20. The busbar of claim 19, wherein the mineral particles comprise from about 10 to about 150 parts by weight per 100 parts by weight of the polymer matrix.

22. 10. The busbar of claim 1, wherein the polymer composition does not contain a filler having an intrinsic thermal conductivity of 100 W / m·K or greater.

23. 10. The busbar of claim 1, wherein the polymer composition exhibits a comparative tracking index of greater than or equal to about 170 volts at a thickness of 3 millimeters as measured in accordance with IEC 60112:2003.

24. 10. A battery assembly including a first battery cell and a second battery cell, wherein the bus bar of claim 1 connects the first battery cell to the second battery cell.

25. 25. An electric vehicle comprising the battery assembly of claim 24.

26. 26. The electric vehicle of claim 25, comprising a powertrain including at least one electric propulsion source and a transmission connected to the propulsion source through at least one power electronics module.

27. 27. The electric vehicle of claim 26, wherein the propulsion source includes the battery assembly.

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