Heat Insulation Device

Abstract

A thermal insulation device comprising a functional filler enclosed within a bag. The bag is made of a film material including at least an inorganic fiber layer and a polymer layer, with the inorganic fiber layer layered on the polymer layer. The bag includes a sealed side formed by sealing the film material. The functional filler is enclosed within the bag so that the functional filler does not leak through the sealed side of the bag. The functional filler includes insulating particles in powder form.

Description

[Technical Field]

[0001] Field The present invention relates to a framed or frameless thermal insulation device / product. The thermal insulation device can be supplemented with one or more flame retardant sheets and / or coatings to further enhance its performance. The thermal insulation device / product can be used in batteries, for example, in electric vehicles. [Background technology]

[0002] background Existing insulation devices used in batteries that contain aerogel as a core material are typically manufactured using aerogel blankets. Aerogel blankets consist of a nonwoven fabric matrix that acts as a reinforcing material for aerogel, which is widely used in the energy infrastructure market. Aerogel blankets have a unique ability to inhibit corrosion under insulation (CUI), making them ideal for use as insulation devices in process lines but not ideal for use in batteries, particularly battery-electric vehicles. The nonwoven fabric matrix of aerogel blankets can affect their insulation performance and mechanical properties, especially under very high compression, which can damage the inorganic fibers and alter the compression characteristics of the aerogel blanket. Summary of the Invention [Means for solving the problem]

[0003] overview According to an example of the present disclosure, there is provided an insulating device as claimed in the independent claims and a battery comprising the claimed insulating device. Some optional features are defined in the dependent claims.

[0004] BRIEF DESCRIPTION OF THE DRAWINGS Examples in the present disclosure will be better understood and readily apparent to those skilled in the art from the following written description, taken by way of example only, in conjunction with the drawings in which: [Brief explanation of the drawings]

[0005] [Figure 1] 1 illustrates an insulating device according to an example of the present disclosure. [Figure 2] 1 illustrates a thermal insulation device according to another example of the present disclosure. [Figure 3a] 1 illustrates a film structure for a thermal insulation device according to an example of the present disclosure. [Figure 3b] 1 illustrates a film structure for a thermal insulation device according to an example of the present disclosure. [Figure 4] 1 illustrates a film material layer according to an example of the present disclosure. [Figure 5a] 1 illustrates a bag with four sealed sides of an insulating device according to an example of the present disclosure. [Figure 5b] 1 illustrates a bag with four sealed sides of an insulating device according to an example of the present disclosure. [Figure 6] 1A-1C show bottom and top views of a bag with three sealed sides of an insulating device according to an example of the present disclosure. [Figure 7a] 1 shows an example of a bag of an insulating device according to an example of the present disclosure with pre-folds (corner folds). [Figure 7b] 1 illustrates a front view of a pre-folded (corner folded) bag according to an example of the present disclosure. [Figure 8a] 1 illustrates a bag fold of an insulating device according to an example of the present disclosure. [Figure 8b] 1 illustrates a bag fold of an insulating device according to an example of the present disclosure. [Figure 9a] 1 shows an example of tape or adhesive applied to a thermal insulation device. [Figure 9b] 1 shows an example of tape or adhesive applied to a thermal insulation device. [Figure 9c] 1 shows an example of tape or adhesive applied to a thermal insulation device. [Figure 9d]1 shows an example of tape or adhesive applied to a thermal insulation device. [Figure 10a] 1 shows an example of a composition including a combination of a thermal insulation device and a thermally expandable sheet / coating according to an example of the present disclosure. [Figure 10b] 1 shows an example of a composition including a combination of a thermal insulation device and a thermally expandable sheet / coating according to an example of the present disclosure. [Figure 10c] 1 shows an example of a composition including a combination of a thermal insulation device and a flame retardant device according to an example of the present disclosure. [Figure 11a] 10 illustrates a step of attaching a frame to a bag of an insulation device according to an example of the present disclosure. [Figure 11b] 10 illustrates a step of sealing a bag of an insulating device according to an example of the present disclosure. [Figure 12a] 1 illustrates a framed insulation device according to an example of the present disclosure. [Figure 12b] 1 illustrates a framed insulation device according to an example of the present disclosure. [Figure 13a] 1 illustrates yet another framed insulation device according to an example of the present disclosure. [Figure 13b] 1 illustrates yet another framed insulation device according to an example of the present disclosure. [Figure 14] 12a and 12b and 13a and 13b show possible dimensions of the example framed insulation devices. [Figure 15] 1A-1C show front, back, and side views of a first example of an insulating device according to an example of the present disclosure having a folded or folded seal. [Figure 15a] 10A-10C show front, back, and side views of a second example of an insulating device according to an example of the present disclosure having a folded or folded seal. [Figure 15b] 10A-10C show front, back, and side views of a third example of an insulating device according to an example of the present disclosure having a folded or folded seal. [Figure 15c] 10A-10C show front, back, and side views of a fourth example of an insulating device according to an example of the present disclosure having a folded or folded seal. [Figure 16] 1 shows a graph of weight versus temperature for E-glass fiber samples. [Figure 17] 1 shows a graph of weight percent versus temperature for a thermal insulation device having a film structure of PET / EG / PE. [Figure 18] 1 shows a table comparing performance data between thermal insulation devices having film structures of PET / EG / PE and PET / AL / PE, respectively. DETAILED DESCRIPTION OF THE INVENTION

[0006] explanation In this disclosure, an electric vehicle (EV) refers to a vehicle that uses one or more electric motors for propulsion and is typically powered by a battery. Such EVs are also known as battery electric vehicles (BEVs). EVs include, but are not limited to, road and rail vehicles (e.g., electric scooters, electric bicycles, electric cars, space rovers, etc.), watercraft and submersibles, electric aircraft (e.g., manned / unmanned aircraft and aerial drones), and electric spacecraft.

[0007] The present disclosure provides a thermal insulation device with a compressible heat shield containing aerogel suitable for use in batteries suitable for, for example, but not limited to, electric vehicles (EVs). The thermal insulation device is relatively lightweight in the context of its application to electric vehicle batteries. The term "thermal insulation device" will be used throughout this disclosure to refer to the thermal insulation device.

[0008] FIG. 1 shows an example of a thermal insulation device 100. The thermal insulation device is a bag (or sachet or packet or package or pouch or container) filled with aerogel sealed within a "braid" structure. The bag 100 includes three film material layers FML1 101, FML2 102, and FML3 103. Film material layer FML1 101 is a cover layer, film material layer FML3 103 is an inner layer, and film material layer FML2 102 is disposed between film material layers FML1 101 and FML3 103. Film material layer FML1 101 is optional and can serve to protect the thermal insulation device from the external environment. Film material layer FML2 102 provides heat and flame insulation and mechanical strength as a reinforcing layer for the thermal insulation device 100. Film material layer FML3 103 serves to maintain the shape of the thermal insulation device 100. In one example, the film material layer FML3 may also form an internal structure that can improve the thermal insulation performance of the thermal insulation device 100 and maintain a uniform distribution of the functional filler. The film material layer may have perforations (or holes or microperforations or pores or openings or orifices (not shown)). The average diameter of the perforations (or holes or pores or openings or orifices) may be 15 μm or less. In another example, the film material layer FML3 and / or one or more other layers may have a characteristic that the perforations are sealed when heated and cooled to form a shape during the heating and cooling step described below (see step (17) in the example manufacturing process for a thermal insulation device). The sides of the film material layer are sealed to form the bag 100, which may contain a functional filler therein. The functional filler may essentially comprise thermal insulation particles. In this disclosure, the term "film material" is used synonymously with "film structure."

[0009] For example, the first functional filler FF1 can include at least one of aerogel powder, fumed silica, and glass bubbles. The aerogel powder includes fine particles of silica (SiO2) with a diameter of 100 μm or less. FF1 is a powder form of insulating particles.

[0010] The second functional filler FF2 can include at least one of titanium dioxide (TiO2), iron oxide (Fe2O3), and aluminum oxide (Al2O3), which can improve the thermal insulation performance by suppressing the increase in thermal conductivity of the thermal insulation device even in high-temperature environments.

[0011] The third functional filler FF3 can include at least one of magnesium hydroxide (MDH), aluminum hydroxide (ATH), and zinc borate. When disposed in an EV battery and a fire occurs in the battery pack, the functional filler 3 can decompose during the combustion process to release water and non-combustible gases such as nitrogen, ammonia, or carbon dioxide, thereby cooling and diluting oxygen and simultaneously producing water, thereby delaying the propagation of the flame.

[0012] In one example, FF1 is a critical component, while FF2 and FF3 are optional and must be uniformly or homogeneously mixed before being filled into the bag of insulation device 100.

[0013] The fourth functional filler FF4 114 may be a reinforcing fiber that encapsulates the functional fillers FF1, FF2, and FF3 123 and is adjacent to the film material layer FML3 103. The functional filler FF4 114 includes at least one of glass fiber, silica wool, mineral wool, ceramic wool, woven fiber, and nonwoven fiber. FF4 may be a glass fiber veil bonded with an acrylic resin, which may be a continuous filament glass fiber product. FF4 114 is an optional layer. Because FF4 114 contacts FF1, FF2, and / or FF3, it may be referred to as the innermost layer in this disclosure. If FF4 114 is not present, FML3 103 would be such innermost layer.

[0014] Table 1 below shows examples of compositions of thermal insulation devices.

[0015] [Table 1]

[0016] In this disclosure, inorganic fibers refer to fibers made from inorganic materials including glass, carbon (referring to inorganic types), ceramic, basalt, asbestos, alumina, wollastonite, potassium titanate, and silicon carbide, etc., individually or in combination.

[0017] Adhesives may be used between layers of film material that are laminated to form a single sheet. In some instances, high lamination temperatures can cause the polymer in one film material layer to penetrate into another film material layer (especially when woven inorganic fibers are employed), making the layer boundaries unclear. Thus, in an actual physical product, the layers may not be stacked in a clear, orderly fashion, as shown in Figure 1, and there may be some overlap or intermingling of the layer materials.

[0018] By utilizing woven inorganic fibers, such as E-glass, with very low organic binder content (approximately 0.05 wt% to 1 wt%) as a component of the film material or filler, the resulting insulation device has a lower overall organic content for better heat and fire resistance while maintaining good dielectric properties and mechanical strength. To achieve higher tensile strength, S-glass fibers can be used. If even higher heat resistance is required, T-glass fibers can be used.

[0019] For the compositions and structures of the above examples in Table 1 above, the typical installation density of the thermal insulation device in the battery module assembly under pressure is about 0.2 to 0.5 g / cm 3 In a relaxed state with no applied pressure, the apparent density of the insulating device is approximately 0.05 to 0.4 g / cm 3 is.

[0020] The thermal insulation device 100 can be made, for example, by the following simplified outline of a manufacturing process. 1. The functional fillers FF1, FF2 and FF3 are mixed homogeneously. 2. Laminate film material layers FML1, FML2, and FML3 to form a single sheet with film material layers FML1 and FML3 on either side of film material layer FML2. Heat / pressure sensitive adhesive may or may not be used between the layers. Roll-to-roll thermal lamination may be used. 3. Forming holes (perforations) in a single sheet, for example using a needle roller (or punch). 4. Using a method such as heat sealing through film material layer FML3, film material layer FML1 is made the outermost surface to form a bag-like structure with one opening. 5. Functional filler FF4 is placed adjacent to the interior surface of the bag to form a void. 6. A mixture of functional fillers FF1, FF2 and FF3 is placed into the void, with functional filler FF4 surrounding the mixture. 7. Close and seal the opening of the bag using a method such as heat sealing to form an insulating device with a "blade" structure.

[0021] Some examples of the thermal insulation device 100 are as follows:

[0022] Referring to FIG. 2 , an example of a thermal insulation device 200 is shown. The thermal insulation device 200 can have a film structure (or film material) including an outer layer 201 (e.g., corresponding to FML1, for protection from external environmental conditions), a middle layer 202 (e.g., corresponding to FML2, for enhanced mechanical strength and protection against heat and flame), and an inner layer 203 (e.g., corresponding to FML3, for fixing the dispersion of the filler inside the cavity and maintaining the shape of the bag). Perforations 210 (or holes or microperforations or pores or openings or orifices) are present in the film material layers FML1 201, FML2 202, and FML3 203. The average diameter of the perforations (or holes or pores or openings or orifices) can be about 15 μm or less. The perforations (or holes or pores or openings or orifices) can allow air to be removed from the thermal insulation device 200. The sides of the film material layer are sealed to form a bag containing the functional filler therein. Functional filler FF4 214 encapsulates functional fillers FF1, FF2, and FF3 223 therein and can act as a reinforcing fiber adjacent to film material layer FML3 203.

[0023] Figure 3a shows an example film structure (or film material) 300a for thermal insulation device 100 of Figure 1 or thermal insulation device 200 of Figure 2, including a first polymer layer 301 (corresponding to FML1) as an outer layer, an inorganic film layer 302 (corresponding to FML2) as a middle layer, and a second polymer layer 303 (corresponding to FML3) as an inner layer. Layers 301, 302, and 303 are bonded together via adhesive 350.

[0024] 3a shows an example of a film structure (or film material) 300a for a thermal insulation device, which includes a polymer layer (corresponding to FML1) as an outer layer, a woven inorganic fiber (glass fiber) layer (corresponding to FML2) as a middle layer, and another polymer layer (corresponding to FML3) as an inner layer. Such a thermal insulation device has been found to have good performance, such as good heat and fire resistance, while maintaining good dielectric properties and mechanical strength.

[0025] 3B shows another example film structure 300b of the thermal insulation device 100 of FIG. 1, including an inorganic film layer 312 (corresponding to FML2) as an outer layer and a second polymer layer 313 (corresponding to FML3) as an inner layer. The polymer layer 313 is partially melted and mixed or infiltrated into the inorganic film layer 312. Such melting, mixing, and infiltration can be achieved, for example, by a thermal lamination process. Notably, there is no clear boundary between the inorganic film layer 312 and the second polymer layer 313.

[0026] In another example, film material layer FML2 in FIG. 2, intermediate layer 202, inorganic film layer 302 in FIG. 3a, and inorganic film layer 312 in FIG. 3b may specifically be a woven textile or fabric of E-glass fiber.

[0027] Table 1a below shows various tests conducted to compare the performance of thermal insulation devices having the film structures PET / AL / PE and PET / EG / PE, respectively. PET / AL / PE refers to a film structure having a polyethylene terephthalate (PET) layer, an aluminum (AL) layer, and a polyethylene (PE) layer. PET / EG / PE refers to a film structure having a polyethylene terephthalate (PET) layer, a glass fiber (EG) layer (e.g., a woven or nonwoven E-glass textile, fabric, or mat) layer, and a polyethylene (PE) layer.

[0028] [Table 2]

[0029] The tensile strength and thermal conductivity of PET / AL / PE and PET / EG / PE are shown in Table 1b below. [Table 3]

[0030] The thermal conductivities of filled (filled with insulating particles, e.g., aerogel powder) and heat-treated insulating devices made from the film materials PET / AL / PE and PET / EG / PE are shown in Table 1c below. [Table 4]

[0031] Tables 1a to 1c above show that the performance of PET / EG / PE is superior to that of PET / AL / PE in terms of electrical insulation, tensile strength, and thermal conductivity. The main contributing factor is the use of an inorganic fiber layer, i.e., EG.

[0032] Table 1a lists the thermal stability, thermal conductivity, and electrical conductivity of the raw materials, i.e., aluminum foil and EG woven fabric mat. While aluminum melts at approximately 660°C, the EG woven fabric mat shows no decomposition after thermogravimetric analysis (TGA-air) testing in air up to 1000°C. This indicates that EG is much more thermally stable at high temperatures than aluminum. The thermal conductivity of the EG woven fabric mat is much lower than that of aluminum foil. The EG woven fabric mat is a good electrical insulator, while aluminum is a good electrical conductor.

[0033] The tensile strength of the perforated film and the thermal conductivity of the film materials PET / AL / PE and PET / EG / PE were investigated. As can be seen from Table 1b, the tensile strength of PET / EG / PE is much higher than that of PET / AL / PE, both in the lamination direction and the cross direction. The thermal conductivity of PET / EG / PE is much lower than that of PET / AL / PE.

[0034] Additionally, the thermal conductivity of filled and heat-treated bags with films PET / AL / PE and PET / EG / PE was investigated. As shown in Table 1c, the thermal conductivity of PET / EG / PE is lower than that of PET / AL / PE at both 24°C and 50°C.

[0035] Referring to Figure 16, the weight of an EG woven mat sample was measured as the temperature increased from 25°C to 1000°C. It can be seen that even at 815°C, where the weight is at its lowest, the weight change is only 0.78% of the initial weight. This indicates that the weight change of EG is negligible in the temperature range from 25°C to 1000°C.

[0036] Referring to Figure 17, the mass of an insulating device with a PET / EG / PE film structure was measured as the temperature increased from 25°C to 1000°C. It can be seen that the mass of the insulating device remained nearly constant over the temperature range of 25°C to 260°C. This indicates that the insulating device is stable over a temperature range well above the battery operating temperature and thermal runaway temperature. Referring again to Figure 17, the residual weight remained at 23% from 600°C to 1000°C, which is contributed by the EG. This indicates that the EG woven mat can provide sufficient heat resistance as a casing material for an insulating device after thermal runaway, which typically reaches a maximum temperature of 900°C.

[0037] As shown in the table in Figure 18, thermal conductivity measurements were performed using a heat flow meter (HFM) on two samples of an insulating device (TB301-2mm) with a PET / EG / PE film structure and two samples of another insulating device (Al-2mm) with a PET / AL / PE film structure. In the table, measured thickness = thickness of each sample measured at the specified load pressure and average temperature, thermal conductivity = heat flow rate per unit area / temperature gradient, and thermal resistance = thickness / thermal conductivity.

[0038] At two applied pressures of approximately 2 kPa, namely 1.9 kPa and 2.3 kPa, and at two temperatures of 24 degrees Celsius and 50 degrees Celsius, respectively, the TB301-2 mm specimen 1 with a thickness of 2.359 mm exhibited thermal conductivities of 0.01405 W / mK and 0.01503 W / mK, respectively, and thermal conductivity of 0.1679 m / s. 2 K / W and 0.157m 2At two applied pressures of approximately 23 kPa, namely 23 kPa and 23.8 kPa, and at two temperatures of 24 degrees Celsius and 50 degrees Celsius, respectively, the 2.313 mm thick TB301-2 mm sample 2 has a thermal conductivity of 0.01517 W / mK and 0.01586 W / mK, respectively, and a thermal resistance of 0.1525 mW / mK. 2 K / W and 0.1459m 2 It has a thermal resistance of 1000 K / W.

[0039] At two applied pressures of approximately 2 kPa, namely 2.2 kPa and 2.4 kPa, and at two temperatures of 24 degrees Celsius and 50 degrees Celsius, respectively, the Al-2 mm sample 3 with a thickness of 2.349 mm exhibited thermal conductivities of 0.01569 W / mK and 0.01613 W / mK, respectively, and thermal conductivity of 0.1497 m / s. 2 K / W and 0.1457m 2 At two applied pressures of approximately 23 kPa, namely 22.9 kPa and 23.6 kPa, and at two temperatures of 24 degrees Celsius and 50 degrees Celsius, respectively, the 2.301 mm thick Al-2 mm sample 4 has thermal conductivities of 0.01593 W / mK and 0.01663 W / mK, respectively, and thermal conductivity of 0.1445 mW / mK. 2 K / W and 0.1384m 2 It has a thermal resistance of 1000 K / W.

[0040] Therefore, at similar thicknesses, the thermal conductivity values ​​of the PET / EG / PE device at two load pressures of approximately 2 kPa and two temperatures of 24 degrees Celsius and 50 degrees Celsius are lower than those of the PETAL / PE device. Furthermore, the thermal resistance values ​​of the PET / EG / PE device are higher than those of the PETAL / PE device. This indicates that PET / EG / PE offers higher resistance to heat transfer.

[0041] The various investigations discussed above reveal that thermal insulation devices having inorganic fiber films (or layers), including but not limited to EG, on an aluminum film or layer have good performance, such as good heat resistance and fire resistance, while maintaining good dielectric properties and mechanical strength, and are therefore excellent candidates in terms of safety for thermal insulation and thermal runaway management in electric vehicle batteries.

[0042] With reference to the examples shown in Figures 2, 3a, and 3b, two pieces of the film structure can be positioned on either side, joined and sealed at the side edges, and then filled with a functional filler to form a bag. The filler can be a free-flowing filler such as an aerogel-based material, i.e., FF1, or can contain additives such as FF2 and / or FF3. The filler can be free-flowing, for example, in powder form. The filler can also include reinforcing fibers that encapsulate the free-flowing fillers FF1, FF2, and / or FF3 and are adjacent to the film material layer FML3. For ventilation and / or degassing purposes, multiple holes or perforations can be provided in all examples of the film structures described in this disclosure. The center-to-center spacing of the perforations can be approximately 3 x 3 mm to provide sufficient passageways for air / pressure release. Figure 4 shows an example of a surface of a film material layer 400 with perforations 410. Figure 5a shows an example of a bag 500 made from the film structure with four-sided seals 570. 5b shows that each sealed area of ​​the seals 570 of the bag 500 can have a seal width of about 6 mm around the perimeter of the bag's body 550. Other types of seals may also be useful, for example, the bag may be a three-sided sealed bag, as described below.

[0043] FIG. 6 shows a bottom view 6A and a top view 6B of an example bag 600 that is rectangular in shape and has three-sided seals. Other bag shapes may also be useful. The three-sided seal includes one vertical or central (linear) seal 660 and two side (linear) seals: top seal 663 and bottom seal 665. Vertical seal 660 is disposed between the two side seals 663 and 665 and is joined to the two side seals 663 and 665 at the ends of vertical seal 660. Vertical seal 660 can be said to be perpendicular to the two side seals 663 and 665, which are disposed horizontally relative to the sides of bag 600. For example, bag seals 660, 663, and 665 may have a seal width of approximately 10 to 20 mm.

[0044] An example of how the bag 600 is formed is outlined below. The film material is prefabricated and can have, for example, the example film structure described above in Table 1 and shown in Figures 1, 2, 3a, and 3b. The film material from a roll of film is wound to form a tubular structure, and two opposing sides of the film material are joined by sealing the vertical seal 660. After the vertical seal 660 is sealed, the bottom seal 665 is sealed to form a preformed bag with an open top or end. A void can be formed through the open top or end of the preformed bag, forming a functional filler FF4 adjacent to the inner surface of the preformed bag. A powder or mixture of functional fillers, such as FF1, FF2, and / or FF3, is introduced or dispensed into the preformed bag through the open top or end, with the functional filler FF4 surrounding the mixture. Once the preformed bag is filled, it is sealed to form top seal 663, closing off the open top or end opening. Alternatively, the filling of functional filler FF4 is omitted and only FF1, FF2 and / or FF3 are filled into the preformed bag.

[0045] Preferably, as shown in FIG. 7a, the horizontal seals, i.e., top seal 763 and bottom seal 765, can be folded or folded at the corners of the seals of the preformed bag 700. Such folding or folding of the seal corners is referred to as a pre-fold. Other pre-fold configurations may also be useful. For example, only one corner of the top seal or bottom seal is pre-folded. In another example, only one corner of the top seal or bottom seal is pre-folded. In the case of angular or rectangular bags, each corner refers to each of the four sharp corners. Pre-folding can be performed to prevent leakage of the filler powder / mixture at each bag corner. Pre-folding is optional but recommended. Pre-folding can be performed using a heat treatment to soften the film material while applying pressure to fold the corners, allowing the corner fold to hold without automatically unfolding.

[0046] Figure 7b shows a front view of the pre-folded (corner folded) bag 700 of Figure 7a. In one example, tape or adhesive 790 is applied to the sealing area on the fold (or sealed side) of the bag, specifically on the top seal (or sealing area) 763 or bottom seal (or sealing area) 765 of the bag, also referred to as the horizontal sealing area of ​​the bag. For example, double-sided tape (or transfer tape) can be applied to the fold of the bag. In another example, adhesive (hot melt adhesive) can be applied to the fold.

[0047] After the tape / adhesive is applied to the horizontal seal area of ​​the bag 700, a folding process can be performed to fold or bend the horizontal seal area so that the tape / adhesive is adhered to the body (or core area) of the bag. By folding or folding the seal area over or under the body of the bag, effective thermal insulation coverage is maximized. Furthermore, when high temperatures and / or pressures are applied to the bag during a later process to evacuate and compress the contents within the bag, the folded or folded seal will more securely press against the body of the bag, and therefore the sealed side or edge of the bag will be less susceptible to opening and spilling the filled contents.

[0048] In one example, as shown in FIGS. 8a and 8b, the top and bottom seals (only one seal 870 is shown for illustrative purposes) with or without pre-folded corners are folded or folded toward the major surface 830 of the body 850 of the bag 800. Adhesive or tape may be placed between the sealed flaps and the bag's major surface 830 (or 890) to affix the flaps to the bag's body 850 (or core portion). Preferably, both the top and bottom sealed flaps are folded / folded toward the same major surface 830 or 890 of the bag's body 850. Alternatively, the top and bottom sealed flaps are folded / folded toward opposite major surfaces 830 and 890 of the bag's body 850. The flaps help to prevent the flaps from interfering with the assembly of the bag into another product, such as an electric vehicle battery. The flaps also provide a containment of the powder at the fold line of the flaps, which helps prevent powder from leaking through the sealed flaps if the powder is not properly sealed or if the seal deteriorates, resulting in a loss of sealing performance due to wear and tear, poor storage, or over time.

[0049] Examples of fully folded or collapsed bags are shown in Figures 15, 15a, 15b, and 15c. These figures will now be described. Note that these figures are not drawn to scale and the thickness of the folds in the side views shown has been exaggerated for better illustration.

[0050] FIG. 15 shows a back view 15A, a front view 15B, and a side view 15C of a folded bag 1500. The folded bag 1500 has a first folded horizontal seal 1502 (or folded top seal), a second folded horizontal seal 1506 (or folded bottom seal), and a folded vertical seal 1504 (or folded middle seal) that is perpendicular to the first folded horizontal seal 1502 and the second folded horizontal seal 1506. The folded vertical seal 1504 can be folded first. Then, the first folded horizontal seal 1502 and the second folded horizontal seal 1506 can be folded. In the example of FIG. 15, all of the folded seals 1502, 1504, and 1506 are visible in the back view 15A. The folded vertical seal 1504 is located at the edge of the folded bag 1500 (with respect to FIG. 15, at the left edge of the folded bag 1500).

[0051] FIG. 15a shows a back view 15D, a front view 15E, and a side view 15F of a folded bag 1510. The folded bag 1510 has a first folded horizontal seal 1512 (or folded top seal), a second folded horizontal seal 1516 (or folded bottom seal), and a folded vertical seal 1514 (or folded middle seal) that is perpendicular to the first folded horizontal seal 1512 and the second folded horizontal seal 1516. The folded vertical seal 1514 can be folded first. Then, the first folded horizontal seal 1512 and the second folded horizontal seal 1516 can be folded. In the example of FIG. 15a, all of the folded seals 1512, 1514, and 1516 are visible in the back view 15D. The folded vertical seal 1514 is located in the central region of the folded bag 1510.

[0052] FIG. 15b shows a back view 15G, a front view 15H, and a side view 15I of a folded bag 1520. The folded bag 1520 has a first folded horizontal seal 1522 (or folded top seal), a second folded horizontal seal 1526 (or folded bottom seal), and a folded vertical seal 1524 (or folded middle seal) that is perpendicular to the first folded horizontal seal 1522 and the second folded horizontal seal 1526. The folded vertical seal 1524 can be folded first. Then, the first folded horizontal seal 1522 and the second folded horizontal seal 1526 can be folded. In the example of FIG. 15b, the folded seal 1524 is visible in the back view 15G, and the folded seals 1522 and 1526 are visible in the front view 15H. A folded vertical seal 1524 is located in the central region of the folded bag 1520 .

[0053] FIG. 15c shows a back view 15J, a front view 15K, and a side view 15L of a folded bag 1530. The folded bag 1530 has a first folded horizontal seal 1532 (or folded top seal), a second folded horizontal seal 1536 (or folded bottom seal), and a folded vertical seal 1534 (or folded middle seal) that is perpendicular to the first folded horizontal seal 1532 and the second folded horizontal seal 1536. The folded vertical seal 1534 can be folded first. Then, the first folded horizontal seal 1532 and the second folded horizontal seal 1536 can be folded. In the example of FIG. 15c, all of the folded seals 1532, 1534, and 1536 are visible in the back view 15J. In the example of Figure 15c, fold seal 1534 is visible in back view 15J and fold seals 1532 and 1536 are visible in front view 25K. Fold vertical seal 1534 is located at an edge of folded bag 2530 (at the right edge of folded bag 1530 with respect to Figure 15c). In another example, fold vertical seal 1534 may be located at edge 1538 of folded bag 1530 (at the left edge of folded bag 1530 with respect to Figure 15c).

[0054] As shown in Figures 15, 15a, 15b, and 15c, folding the sealing flaps over or under the core area of ​​the bag can maximize the effective insulating coverage of the insulating device. Additionally, when high temperatures and pressures are applied to the top and bottom of the bag, the sealed flaps can be more securely pressed against the core area of ​​the bag and therefore less susceptible to opening and spilling the filled contents. Other configurations of the sealing flaps folded over or under the core area of ​​the bag may also be useful.

[0055] 9a-9d show that the bag can be provided with adhesive / tape on one major (front or back) surface of the bag. Thus, the bag can be adhered to a surface as needed for the bag's application. If the bag is not immediately assembled to another component, such as an electric vehicle battery, a release liner can be provided on the adhesive / tape. A release liner or release paper is essentially a paper or plastic-based film sheet used to prevent premature adhesion of adhesive surfaces. The bag / insulation device may also be labeled. An inkjet printer or laser marking system can be used for labeling. The labeling can include product information (e.g., model number, batch number, etc.) and / or manufacturing date.

[0056] The adhesive may be in liquid form and sprayed onto the major surfaces of the insulating device. Alternatively, the major (front and back) surfaces of the insulating device may be provided with a double-sided or transfer tape with a release liner on one side. The insulating device may have tape / adhesive and a release liner on one or both of its major surfaces.

[0057] Specifically, a taping process can be used to apply adhesive to the insulating device. In the case of adhesive application, the adhesive is prepared and applied to the desired surface of the insulating device. A release liner is then applied to the applied adhesive. In another example, a single-sided tape having a release liner on one side may be used. In this case, the adhesive is first applied to the desired surface of the insulating device, and then the side of the single-sided tape without the release liner is applied to the applied adhesive. In the case of a double-sided tape or transfer tape having two sides with release liners, the release liner or one side of such a tape is first removed to apply the tape to the desired surface of the insulating device. The tape can be cut to size before or after (preferably before) the tape is adhered to the desired surface of the insulating device.

[0058] 9a-9d illustrate different scenarios 908, 910, 912, and 914 of how tape can be applied to one or both major surfaces or faces of an insulating device. The actual scenario depends on the application and can be any of these scenarios. For example, for scenario 908, tape or adhesive 908a is applied to the entire major surface of the insulating device. For scenario 910, tape or adhesive 910a is applied over a predetermined surface area of ​​the insulating device. For scenario 912, tape or adhesive 912a is applied over a surface area that varies with the width of the insulating device. That is, the surface area to which the tape or adhesive is applied is a function of the width. For example, the surface area can be located the same distance from the width boundary edges of the insulating device. Such surface area can extend substantially along the length of the insulating device. Width boundary edges refer to opposite edges that are separated by a distance equal to the width of the insulating device. For scenario 914, tape or adhesive 914a is applied over a surface area that varies with the length of the insulating device. That is, the surface area to which the tape or adhesive is applied is a function of length. For example, the surface area can be located the same distance from the length boundary end of the insulating device. The length boundary end refers to the end located opposite each other and separated by the distance of the length of the insulating device. Furthermore, two or more other tapes or adhesives 914b covering a given surface area may be applied at a given location. In this scenario, the tapes or adhesives 914b are relatively small in size compared to the tapes or adhesives 914a. Removable release liners should be provided for the applied tapes or adhesives 908a, 910a, 912a, 914a, and 914b to enable them to be attached to surfaces as needed.

[0059] 10a-10c show four products (or compositions or devices) 1010, 1020, 1030, and 1000. A thermally expandable (fire-retardant) sheet 1012 (described below) can be adhered or placed on one or more major surfaces of the thermal insulation device 1008. Instead of the thermally expandable sheet 1012, a thermally expandable coating (also given reference numeral 1012) can be coated on one or more major surfaces of the thermal insulation device 1008. Examples of such thermally expandable coatings include fire-retardant paints and impregnation liquids that can be used to produce fire-retardant devices of the type described below.

[0060] In FIG. 10 a, product 1010 comprises an insulating device 1008 and two thermally expandable sheets or coatings 1012 disposed on two major surfaces of insulating device 1008 .

[0061] 10b, product 1020 comprises two thermal insulation devices 1008 disposed on two major surfaces of one layer of thermally intumescent sheet 1012. The thermally intumescent sheet 1012 in product 1020 may also be a thermally intumescent coating (also given reference number 1012). Product 1030 comprises one thermal insulation device 1008 disposed on one major surface of one layer of thermally intumescent sheet 1012.

[0062] 10c, product 1000 comprises an insulating device 1008 and two flame retardant devices 1002 disposed on two major surfaces of insulating device 1008. An adhesive in the form of tape or a coated film such as adhesive film 1014 can be used to adhere the two flame retardant devices 1002 to insulating device 1008. The flame retardant devices are not necessarily thermally expandable. However, flame retardant device 1002 is preferably a thermally expandable sheet, such as the flame retardant devices described below.

[0063] The products 1000, 1010, 1020 and 1030 shown in Figures 10a-10c can be used with or without the frame structure described below.

[0064] In this disclosure, the flame-retardant device refers to a thermally expansive sheet suitable for, but not limited to, thermal runaway management in electric vehicle batteries. The thickness of the sheet is less than 2 mm, preferably 1 mm or less. For example, the thermally expansive sheet is formed by impregnating nonwoven inorganic fibers with an alkali silicate-based solution (referred to as an "impregnation liquid" in this disclosure). The impregnation liquid may be a water-based thermally expansive coating containing an aerogel. The impregnation liquid may include an additive, and the thermally expansive sheet, after drying and / or curing, has an alkali silicate-based coating containing the additive. This flame-retardant device is FR device 1002 in FIG. 10c. Thermally expansive sheet 1012 in FIGS. 10a and 10b may also be this flame-retardant device. The term "flame-retardant device" refers to the flame-retardant device throughout this disclosure.

[0065] The composition of the thermally expandable sheet (after drying) and the composition of the impregnation liquid for an example of a flame-retardant device are described below.

[0066] The thermally expandable sheet can include a nonwoven inorganic fiber mat (or fabric), such as ECR-50 (a type of E-glass) manufactured by Owen's Corning. The impregnation liquid used in this product contains a sodium silicate-based binder and aerogel particles with hydrophobic surface groups. The aerogel particles have a particle size of 10 to 60 μm and a porosity of over 90%. Alumina (a type of metal oxide) and metal dihydroxide (a type of metal hydroxide) are added as additives to the impregnation liquid to improve the mechanical robustness, thermal insulation, and flame retardancy of the charcoal.

[0067] Tables 2a and 2b below show examples of compositions of flame retardant devices after drying and compositions of impregnation liquids. Table 3 below shows selected properties of thermally expandable sheets.

[0068] [Table 5]

[0069] [Table 6]

[0070] [Table 7]

[0071] To improve the ability to spread and wet the nonwoven inorganic fiber mat, a surfactant stable in the pH range of 2 to 12 may be added to the impregnation solution. Preferably, the surfactant is selected from the group consisting of amine oxides, alkyl carbohydrate esters, alkoxylated polysiloxanes, and polyalkyl acrylates. The amount of surfactant added may be 0.2 to 0.5 wt% of the impregnation solution, while a preferred amount is 0.2 to 1.2 wt% of the thermally expandable sheet.

[0072] Regarding the nonwoven inorganic fiber mat for flame retardant devices, in addition to E-type glass, S-type glass is another preferred option. When E-type glass is used, E-type glass with the boron oxide component removed is the most preferred. The fiber diameter and length should be between 10-15 μm and 15-60 mm.

[0073] Other insulating additives that are microporous (i.e., additives that allow the formation of carbides with a tight network structure) can also be used, such as fumed silica, hollow microglass spheres, etc. Other suitable carbide strength-imparting ceramic additives, such as combinations of metal oxides, hydroxides, carbonates, silicates, and / or powders, can also be used.

[0074] In addition to the above-mentioned components, the thermally expandable sheet may optionally contain 1 to 10 wt % of an opacifier such as iron oxide, silicon carbide, and / or titania. The opacifier provides high-temperature insulation and serves to reflect and thereby reduce heat transfer via radiation at high temperatures.

[0075] To improve the flexibility and water resistance of the thermally expandable sheet, organic additives can be added at the impregnation station (where the nonwoven inorganic fiber mat and the impregnation liquid are impregnated). Preferred examples of organic additives include glycerol and polyvinyl alcohol.

[0076] The impregnation solution is prepared by sequentially adding an alkali silicate solution and one or more surfactants, followed by an insulating agent, a char strength agent, and other additives, and finally the required amount of water, stirring and mixing for 15 minutes after each step (i.e., after each component is added sequentially), and then stirring and mixing the solution containing all the added components for an additional 2 to 3 hours. The curing agent is the last component to be added to the impregnation solution, just before impregnating the nonwoven inorganic fiber mat. The viscosity is preferably 200 to 500 centipoise (cPs).

[0077] The curing agent is preferably sodium fluorosilicate or potassium methyl siliconate (most preferred).

[0078] When opacifier, hardener and water are added, the composition of the impregnation liquid is in Table 4 as follows:

[0079] [Table 8]

[0080] To produce a thermally expandable sheet, a nonwoven inorganic fiber mat is first layered onto a non-stick polymer sheet and impregnated with an alkali silicate-based aqueous solution (ie, the impregnation liquid).

[0081] Various impregnation methods can be employed, such as spraying, brushing, and / or doctor blading. Preferably, doctor blading is employed for better thickness control and feasibility for mass production. Drying is then carried out at a suitable temperature (e.g., room temperature) to remove water without causing defects such as warping. Optionally, curing can be carried out at a higher temperature (e.g., by microwave heating) to speed up the process.

[0082] Other carbide strength-enhancing additives that can be added include zirconium oxide and colloidal silica. Sodium silicate is defined by the molar ratio of silica to sodium oxide. Increasing the silica ratio allows for the formation of stronger carbides, and this increase can be regulated by the addition of colloidal silica.

[0083] An example of a flame-retardant device may have the following thermal expansion characteristics: it can rapidly respond at temperatures above 175 degrees Celsius, expand to five times its original thickness, fill voids, and provide an insulating foam that reduces heat transfer; it is non-flammable; and it has an inorganic formulation. An example of a flame-retardant device may be a flexible sheet material manufactured in bulk rolls for lamination and die-cutting. The flame-retardant device may be available in standard thicknesses of 0.4 mm to 1.0 mm. See Tables 4a and 4b below for details of this example of a flame-retardant device.

[0084] [Table 9]

[0085] [Table 10]

[0086] 11a and 11b show an example of a step of framing and sealing the bag of the insulation device 1100. In this example, the bag of the insulation device 1100 is sealed with a three-sided seal and has three sealed areas 1170. It should be understood that in other examples, a four-sided sealed bag may be used if desired. These three sealed areas 1170 include first and second horizontal seal areas having the width of the bag 1100 as their length, which are located on opposite edges of the bag 1100. A third center seal is perpendicular to the first and second horizontal seal areas.

[0087] First, the insulating device 1100 is inserted into the main opening 1140 of a single-piece frame structure 1180 (e.g., a silicone frame) to form a framed insulating device 1185. Second, electrically insulating film layers 1190 are added or placed, completely or partially, on the major surfaces of the framed insulating device 1185. Heat and pressure are applied to these film layers 1190 to heat them and soften and / or melt them into a seal.

[0088] The framed insulating device can also include a combination of an insulating device and a flame retardant device. If a framed sealed insulating and flame retardant device is manufactured using the framing and sealing process described above, the described insulating device 1100 may be replaced by, for example, an insulating device bonded to two flame retardant device layers. Other combination configurations of insulating and flame retardant devices may also be useful.

[0089] Figures 12a and 12b show a first example of a framed insulation device 1200. Figure 12a is a top view 12A of the framed insulation device 1200, and Figure 12b is a cross-sectional view 12B thereof. The framed insulation device 1200 includes an insulation device 1208 and two layers of a flame-retardant (FR) device 1202. Each layer of the FR device 1202 is disposed on either side of a major surface of the insulation device. The insulation device 1208 is sandwiched between the two layers of the FR device 1202. A frame structure 1204, comprised of upper and lower frame layers, is provided to cover the sides or edges of the insulation device 1208 along its periphery. A layer of sealant 1206 is provided on each major surface of the framed insulation device 1200. The sealant 1206 forms an outer protective layer on the exposed major surfaces of the two layers of the FR device 1202.

[0090] Figures 13a and 13b show another example of a framed insulation device 1300. Figure 13a is a top view 13A of the framed insulation device 1300, and Figure 13B is a cross-sectional view 13B thereof. The framed insulation device 1300 includes an insulation device 1308, the sides or edges of which are sandwiched along (or around) the periphery of the insulation device 1308 by a frame structure 1304 made up of upper and lower frame layers. A layer of sealant 1306 is provided on each major surface of the framed insulation device 1300. The sealant 1306 forms an outer protective layer on the exposed major surfaces of the insulation device 1308.

[0091] Table 5a below shows an example of specifications for a frame structure having two frame layers.

[0092] [Table 11]

[0093] Examples of size and weight ranges for framed insulation devices and their combinations with and without frames and with and without flame retardant devices for electric vehicle battery applications are shown in Table 5b below.

[0094] [Table 12]

[0095] FIG. 14 shows a top view 13A of FIG. 13a, a cross-sectional view 13B of FIG. 13b, and an enlarged cross-sectional view 12B of FIG. 12b. FIG. 14 shows specific examples of possible dimensions for a first example of a framed insulation device 1200 and a second example of a framed insulation device 1300. The length and width of the framed insulation device 1300 can be approximately 148 mm and 98 mm, respectively. The framed insulation device 1200 (top view 12A not shown in FIG. 14) can similarly have the same length and width. The thickness of the framed insulation device 1200 and the framed insulation device 1300 can be approximately 3 mm, excluding the seals. Each of the two layers of the frame structure 1204 in the framed insulation device 1200 and the framed insulation device 1300 can be approximately 1.5 mm thick. The insulation device 1308 in the framed insulation device 1300 can have a thickness of 2 mm. Each of the two layers of flame retardant device 1202 in framed insulation device 1200 can be approximately 0.5 mm thick. Insulation device 1208 in framed insulation device 1200 can have a thickness of 2 mm.

[0096] An example of a manufacturing process for a thermal insulating device is described as follows.

[0097] In step (1), raw materials are received and verified to ensure the correct materials and quantities are received.

[0098] In step (2), the raw materials are stored in a raw materials warehouse.

[0099] In step (3), the powders required to produce the mixed powder (i.e., the final powders for filling each bag of the insulation device) are unpacked and placed into one or more mixing buffers. A buffer refers to a container or reservoir for holding or storing powder. The buffers may be hoppers. Each mixing buffer can accommodate a different type of powder. For example, one mixing buffer can hold silica aerogel particulates, while another can hold metal oxide (opacifier) ​​powder. If other materials are added, additional mixing buffers can hold them. The mixing buffers may be bowl- or funnel-shaped components with a large receiving area and sufficient depth or height to hold the powder.

[0100] In step (4), powder is dosed or dispensed into the mixer from one or more mixing buffers.

[0101] In step (5), the mixer mixes the powders that are introduced or dispensed into the mixer for mixing. A mixer agitator or other suitable equipment can be provided to homogeneously mix the dispensed powders.

[0102] In step (6), the mixing quality is checked, for example, computer vision or X-ray can be used to detect whether the mixed powder is sufficiently homogeneous.

[0103] In step (7), the mixed powder that passes the quality check is dispensed or transported to a mixed powder buffer or reservoir.

[0104] In step (8), the mixed powder obtained after step (7) is conveyed to or poured into a filling hopper that fills the powder into a bag. The filling hopper is attached to an apparatus or machine and configured to supply the mixed powder to the apparatus.

[0105] In step (9), the apparatus forms the film and / or bags, dispenses the powder, fills the formed bags, seals the bags, and cuts the filled bags into individual bag sizes. For example, a vertical or horizontal form, fill, and seal machine can be used. After step (9), the apparatus forms bags containing the mixed powder. Each bag can be made from one or more rolls of film that are fed into the forming apparatus to form the bags. Sheets of film can be perforated and packaged onto the roll of film. Each sheet of film can include multiple layers; for example, film material layers FML1 and / or FML2 and / or FML3 can form multiple layers. In one example, the film material for forming the bags is prefabricated and provided in a bulk roll for bag formation. The perforations must be small enough to prevent powder from leaking through the perforations.

[0106] In step (10), a quality check is performed on the filling. This is done through a weight check. Each bag is weighed to see if it meets the predetermined weight requirement. Bags that do not meet the weight requirement are rejected and stored in a rejected product container. Depending on the condition of the rejected products, each of them may be weight checked again or replenished. Good bags or bags that pass the quality check are transported to the next station for further processing. Assuming that a bag with an angular or rectangular shape is formed, at the end of step (10), the formed bag will have three or four sides with folds formed by the side seals made by the device in step (9).

[0107] In step (11), a first cleaning step is performed to clean each bag that passed the quality check in step (10). After cleaning, an optional quality check is performed on each bag for cleanliness. Cleaning can be performed by air purging, i.e., air is blown onto the bag to clean it, and / or the bag is subjected to vacuum suction, where powder (if present) is sucked out of the bag, and / or by any other appropriate suitable cleaning method. This first cleaning step is useful, for example, if powder leaks (or spills) at the filling hopper or in the device, or if a bag ruptures or leaks in steps (9) or (10). Step (11) is optional, but recommended.

[0108] In step (12), pre-folding is performed. Such pre-folding refers to folding or bending each corner of each bag. In the case of angular or rectangular bags, each corner refers to each of the four sharp corners. This is done to ensure that no powder leakage occurs at the corners of each bag. Step (12) is optional, but recommended.

[0109] In step (13), after the pre-fold has been made, or if the pre-fold has been skipped, adhesive or tape is applied to the folds of the bag in preparation for folding or folding the folds and attaching them to the body of the bag.

[0110] In step (14), the flap of each bag is folded or folded over and affixed to the body of the bag. This folding step helps to keep the flap out of the way of assembly of the bag into another product, such as an electric vehicle battery. The flap also provides a seal for the powder at the fold line of the flap, which helps to prevent the powder from leaking through the sealed flap if the powder is not properly sealed or if the seal deteriorates, resulting in a loss of seal performance due to wear and tear, inadequate storage, or over an extended period of time.

[0111] In step (15), a quality check for aliasing is performed, which can use computer vision techniques.

[0112] In step (16), each bag is leveled to ensure uniform distribution of the powder inside the bag. This can be done, for example, by vibration. This step can be performed independently before degassing or can be combined with the degassing process described below.

[0113] In step (17), each folded bag is transported to a station where the bag is 1) degassed, 2) heated, and 3) cooled. These three steps can be performed as follows: During degassing, the bag is compressed to force air out of the bag. Degassing and compression can help compress the functional filler within the bag. Such degassing involves applying pressure to the major surfaces of the bag to flatten it. The film layer of the bag contains micro-perforations, allowing gas to escape through these perforations. After or during the application of pressure, the bag is heated, and during heating, for example, the film layer softens to form the bag, which helps release more gas from the bag. After heating, the bag is cooled. The cooling can be active cooling, in which the temperature is actively reduced to rapidly cool the bag. Alternatively, cooling can occur naturally as well. Preferably, the bag is under compression throughout the three steps.

[0114] In step (18), a second cleaning step is performed to clean each bag evacuated in step (17). After cleaning, an optional cleaning quality check can be performed as well. Cleaning can be performed by air purging, i.e., air is blown onto the bag to clean it, and / or by subjecting the bag to vacuum suction, where powder (if present) is sucked out of the bag, and / or by other suitable cleaning methods. This second cleaning step is useful, for example, if powder leaks (or spills) from the bag or if the bag ruptures during step (16). Step (18) is optional, but recommended.

[0115] In step (19), an optional but recommended final inspection (quality check) must be performed on each bag. Using computer vision techniques or other suitable methods, the bag's weight, dimensions, visual appearance, wrinkles and flatness, powder leakage and / or thickness, etc., are inspected to ensure that quality requirements are met. After inspection, an optional bag labeling or marking step can be performed. This labeling or marking step can involve, for example, using an inkjet or laser printer to label or mark the outer film layer of each bag with manufacturing and / or product details, etc.

[0116] In step (20), an optional taping step of the bag may be performed to provide the bag with tape, which allows it to adhere to a surface as needed for the bag's application. If the bag is not immediately assembled to another component, such as an electric vehicle battery, a release liner can be provided over the tape. Release liners or release papers are essentially paper or plastic-based film sheets used to prevent adhesive surfaces from prematurely adhering.

[0117] In step (21), the quality of the taping performed in step (20) is checked to ensure proper application of the taping and / or release liner, which can be done using computer vision techniques.

[0118] In step 22, the bags are packaged and prepared for delivery, which can be done, for example, by first stacking and tying the bags into bundles, which are then packed into cardboard boxes.

[0119] In step (23), the bag-filled cartons are stacked on pallets.

[0120] In step 24, the pallets are transferred to a pre-shipment warehouse and prepared for shipment.

[0121] Generally, the key components of the manufacturing process described above are forming the bag, filling the bag with powder, folding back the sealed sides of the bag, degassing and heat treating.

[0122] An example of a method for manufacturing a framed insulating device and combinations thereof is described as follows: There may be a bag preparation and filling step (A), a framing step (B), an evacuation step (C), a flame retardant (FR) device insertion step (D), and a sealing step (E). The framed insulating device comprises an insulating device in the form of a bag containing the functional filler described above.

[0123] Step (A) of preparing and filling the bag can be steps (1)-(15) described above (with or without the steps described as optional). The product of step (A) can be a bag of insulated device that has not yet been evacuated, heat treated, and cooled. Alternatively, the product of step (A) can be a bag made by steps (1)-(24) (i.e., a bag that has already been evacuated, heat treated, and cooled).

[0124] The framing step (B) receives the product of step (A). The product of step (B) is a framed insulation device. In an example of a frame structure including two parts or two frame layers, a pick-and-place robot, such as a six-axis robot, can be used during frame assembly. In the first step, the lower frame is placed on a platform or fixture. In the second step, one or more bags of the insulation device are placed on the lower frame. In the third step, the upper frame is placed on the insulation device. After the third step, the insulation device is sandwiched between the upper and lower frames. If the insulation device is bonded to the upper and lower frames, there is an intermediate bonding step between the first, second, and third steps. Bonding can be performed using an adhesive. The adhesive can be in the form of a tape, such as double-sided tape or transfer tape. In the first scenario, the upper frame can be glued to the lower frame, or in the second scenario, the upper frame can be glued to the bag and the lower frame can be glued to the bag. The second scenario may apply when the bag is thick and the upper frame cannot contact the lower frame when placed on the bag. Although a frame structure having two frame layers is described, a frame structure that is a single-piece construction may be adapted for the processes described herein.

[0125] The degassing step (C) can be performed by a degassing conveyor device / system. This degassing conveyor system may or may not perform a heat treatment on the framed bags. The purpose of degassing is to remove excess air from the inside of each bag of the insulation device if the bag has not been previously degassed or has not been sufficiently degassed. Degassing also serves to secure the frame structure of each bag (i.e., to secure the two frame layers together or on the two frame layers). An example of a degassing conveyor device / system includes an upper conveyor and a lower conveyor. The upper (or upper) conveyor includes multiple interconnected upper plates arranged to move in an endless loop, and the lower (or lower) conveyor includes multiple interconnected lower plates arranged to move in an endless loop. Each upper plate cooperates with the lower plate to compress the framed bags of the insulation device arranged between them and degas the framed bags. The distance between the upper and lower plates can be adjusted to apply or release pressure to the framed bag.

[0126] Each upper and / or lower plate may be configured to facilitate degassing of each bag by vacuum suction. The surface of the upper and / or lower plate that contacts the framed bag may be perforated with a plurality of perforations and connected to a vacuum suction unit that draws or sucks air through the perforations. When the perforated surface of the upper or lower plate contacts the framed bag, the bag is degassed using vacuum suction.

[0127] After or before degassing, a FR device insertion step (D) can be performed to insert one or more FR devices into the framed insulation device. The input to this process is a framed insulation device having openings defined by the frame layers that expose the insulation devices. Each frame layer covers the periphery of the insulation device and has a hollow center corresponding to such opening. In the first step, a first flame retardant device is placed within a first opening in the upper or lower frame layer. After insertion, the first flame retardant device contacts the insulation device. In the second step, the upper or lower main surface of the framed insulation device is sealed to secure the first flame retardant device in the first opening. In the third step, the framed insulation device is inverted. In the fourth step, a second flame retardant device is inserted into a second opening in the lower or upper frame layer, respectively. After insertion, the second flame retardant device contacts the insulation device. In the fifth step, the lower or upper surface of each of the framed insulation devices is sealed to secure the second flame retardant device in the second opening. Details of the sealing process are described below.

[0128] Step (E) preferably involves sealing the framed insulation device immediately after the FR device is inserted into the framed insulation device. After insertion of the first flame retardant device, the outer major surface of the framed insulation device with the inserted first flame retardant device is sealed before the framed insulation device is inverted for insertion of the second flame retardant device. A sealant layer is applied over the framed insulation device containing the inserted first flame retardant device. After the framed insulation device is inverted and the second flame retardant device is inserted, another sealant layer is applied over the outer major surface of the framed insulation device with the second flame retardant device inserted into the framed insulation device. The final sealed framed insulation device contains the insulation device between the two flame retardant devices and the two frame layers, and the two major surfaces of the insulation device are sealed. A label (or seal) applicator is a possible instrument used to apply the seal. The seal can be a coating or thin film of a suitable plastic material (e.g., a polymer sheet). In another example, electricity is passed through a thin layer of sealing material to heat the thin layer and cause it to soften and / or melt into a seal that can be attached to the outer major surface of the framed insulating device.

[0129] Examples of the present disclosure may have the following features: Reference numbers in parentheses refer to the reference numbers of elements in the figures.

[0130] A thermal insulating device (e.g., 100, 200, 500, 600, 1010, 1020, 1030, 1000, 1200, 1300, 1500, 1510, 1520, 1530), A functional filler (e.g., FF1, FF2, and / or FF3) enclosed in a bag, the bag comprising at least: an inorganic fiber layer (e.g., FML2 102); A polymer layer (e.g., FML3 103) and Functional fillers made from film materials containing (e.g., FF4, a combination of FML1 to FML3; 300a, 300b, 400) Equipped with an inorganic fiber layer is layered on the polymer layer; the bag includes a sealed side formed by sealing a film material; a functional filler is enclosed within the bag such that the functional filler does not leak through the sealed sides of the bag; The functional filler includes heat insulating particles in powder form (e.g., FF1). Referring to Table 1, other combinations of inorganic fiber layers layered on top of polymer layers include: a) FML1, FML2 or FML3 as a polymer layer in contact with FF4 as an inorganic fiber layer; b) FML2 or FML1 as an inorganic fiber layer in contact with FML2 or FML1 as a polymer layer, respectively; c) FML3 as an inorganic fiber layer in contact with FML1 as a polymer layer (in this case, FML2 is absent) It should be understood that it is possible to do so.

[0131] It should be noted that "layered over" can mean that an inorganic fiber layer is overlying a polymer layer, or that a polymer layer is overlying an inorganic fiber layer.

[0132] The film material (e.g., 300a) is a cover layer (e.g., FML1, 201, 301) layered over the inorganic fiber layer such that the inorganic fiber layer is between the cover layer and the polymer layer; and The cover layer is a polycarbonate (PC) film, a polyimide (PI) film, a polyethylene terephthalate (PET) film, a cyclic olefin polymer (COP) film, a non-oriented polypropylene (CPP) film, or a nylon film.

[0133] The cover layer may be blended with the inorganic fiber layer so that there is no clear boundary between the inorganic fiber layer and the cover layer.

[0134] Alternatively, the film material may be a cover layer (e.g., FML1 101) layered over the inorganic fiber layer such that the inorganic fiber layer is between the cover layer and the polymer layer; and The cover layer is a woven ceramic fiber textile.

[0135] The film material is Innermost layer (e.g., FF4 114) and The polymer layer is layered on the innermost layer, The innermost layer is in contact with the functional filler, and the innermost layer is At least one of glass fiber, silica wool, mineral wool, ceramic wool, woven fiber textile, and nonwoven fiber textile It is made of.

[0136] The innermost layer (eg, FF4 114) may be a fiberglass veil bonded with an acrylic resin.

[0137] The inorganic fiber layer may be woven.

[0138] The inorganic fiber layer may be a woven glass fiber textile, and the glass fiber may be E-glass fiber.

[0139] The polymer layer may be polycarbonate (PC), polyethylene (PE), polypropylene (PP) or polyvinyl chloride (PVC), or Composite materials containing PC, PE, PP and / or PVC and flame retardants It can be made with.

[0140] Functional fillers are at least one of aerogel powder, fumed silica, and glass bubbles; At least one of titanium dioxide (TiO2), iron oxide (Fe2O3) and aluminum oxide (Al2O3) may include:

[0141] Functional fillers are At least one of magnesium hydroxide (MDH), aluminum hydroxide (ATH), zinc borate, aluminum polyphosphate, and melamine cyanurate It may further include:

[0142] The polymer layer (eg, 313) may be mixed with the inorganic fiber layer (eg, 312) so that there is no clear boundary between the inorganic fiber layer and the polymer layer (eg, 300b).

[0143] Two or more layers of film material can be attached to one another via an adhesive (eg, 350).

[0144] A bag (e.g., 600, 1100, 1170, 1500, 1510, 1520, 1530) may include only three sealed sides, including one linear central seal (e.g., 660, 1504, 1514, 1524, 1534) and two linear side seals (e.g., 663, 665, 1502, 1506, 1512, 1516, 1522, 1526, 1532, 1536), where the central linear seal is perpendicular to the two side linear seals.

[0145] A bag (eg, 500) may include only four sealed sides (eg, 570).

[0146] The corners of the bag (eg, 780) can be folded (eg, pre-folds as shown in Figures 7a and 7b) to prevent the functional filler from leaking out through the corners.

[0147] The sealed sides of the bag (e.g., 700) can be folded and attached to the body of the bag (e.g., the flaps shown in Figures 8a and 8b) to prevent the functional filler from leaking through the sealed sides of the bag.

[0148] The film material can include a plurality of perforations (eg, 210, 410), the perforations and the functional filler being sized such that the functional filler does not leak through the perforations.

[0149] The bag can be evacuated to compress the functional filler enclosed within the bag.

[0150] The thermal insulation device (eg, 1010, 1020, 1030) can include one or more thermally expandable, flame-retardant coatings applied to one or two major surfaces of the bag.

[0151] The thermal insulation device (eg, 1000, 1200) may include one or more thermally expandable, fire-retardant sheets attached to one or two major surfaces of the bag.

[0152] The thermal insulation device (e.g., 1020) Two bags and one or more thermally expandable flame-retardant sheets disposed between the two bags; It can be equipped with:

[0153] The thermally expandable flame retardant sheet (eg, flame retardant device) can be a nonwoven fiberglass mat coated or impregnated with a polymeric or inorganic thermally expandable solution.

[0154] The insulation device can include a frame structure (eg, 1180, 1204, 1304) positioned around the perimeter of the insulation device.

[0155] The frame structure of the thermal insulation device may be made of silicone.

[0156] The frame structure (e.g., 1204, 1304) a first frame layer attached over the first surface of the thermal insulation device; a second frame layer attached to a second side of the insulating device opposite the first side of the insulating device; may include:

[0157] The frame structure may be a single piece frame structure (eg, 1180).

[0158] The thermal insulation device may include one or more sheets (eg, 1206, 1306, 1190) of electrically insulating film material for sealing one or more major exterior surfaces of the thermal insulation device, respectively.

[0159] The insulating device may include tape and / or adhesive (e.g., 908a, 910a, 912a, 914a, and 914b) applied onto one or more outer surfaces of the insulating device, with a release liner over the tape and / or adhesive to allow for adhesion of the insulating device to another object, if desired. Examples are 908, 910, 912, and 914 in Figures 9a-9d.

[0160] The functional fillers may be non-matrix. They are non-matrix in the sense that there is no network formation, no cross-linking with the binder, and / or no structural reinforcing material present in the functional filler. In this case, the functional fillers differ from the aerogel blankets discussed in the background section of this disclosure.

[0161] The battery may include a thermal insulation device.

[0162] In this disclosure, unless the context clearly indicates otherwise, the term "comprising" has the non-exclusive meaning of the word in the sense of "including at least," rather than the exclusive meaning of "consisting only of." The same applies to the corresponding grammatical variations of other forms of the word, such as "comprise," "comprises," etc.

[0163] While this disclosure has described the invention in terms of several examples, embodiments, and implementations, the invention is not so limited and encompasses various obvious modifications and equivalent arrangements that fall within the scope of the appended claims. Although features of the invention are expressed in any combination among the claims, it is contemplated that these features can be arranged in any combination and order.

Claims

1. 1. A thermal insulation device comprising: A functional filler enclosed in a bag, the bag comprising at least: Inorganic fiber layer a polymer layer; The film is made of a film material comprising the inorganic fiber layer is layered on the polymer layer; the polymer layer is in contact with the functional filler; or the polymer layer is layered on an innermost layer in contact with the functional filler, the innermost layer being made of at least one of glass fiber, silica wool, mineral wool, ceramic wool, woven fiber textile, and nonwoven fiber textile; the bag includes a sealed side formed by sealing the film material; the functional filler is sealed within the bag so that the functional filler does not leak through the sealed side of the bag; the functional filler comprises insulating particles in powder form; Insulation device.

2. The film material is a cover layer layered on the inorganic fiber layer such that the inorganic fiber layer is between the cover layer and the polymer layer; Equipped with 2. The thermal insulation device of claim 1, wherein the cover layer is a polycarbonate (PC) film, a polyimide (PI) film, a polyethylene terephthalate (PET) film, a cyclic olefin polymer (COP) film, a plain polypropylene (CPP) film, or a nylon film.

3. The thermal insulation device of claim 2 , wherein the cover layer is intermixed with the inorganic fiber layer such that there is no distinct boundary between the inorganic fiber layer and the cover layer.

4. The film material is a cover layer layered on the inorganic fiber layer such that the inorganic fiber layer is between the cover layer and the polymer layer; Including, The thermal insulation device of claim 1 , wherein the cover layer is a woven inorganic fiber textile.

5. 10. The thermal insulation device of claim 1, wherein the innermost layer is a fiberglass veil bonded by an acrylic resin.

6. The thermal insulation device according to any one of claims 1 to 5, wherein the inorganic fiber layer is woven.

7. 7. The thermal insulation device of claim 6, wherein the inorganic fiber layer is a woven fiberglass textile and the glass fibers are E-glass fibers.

8. The polymer layer is selected from the group consisting of polycarbonate (PC), polyethylene (PE), polypropylene (PP), and polyvinyl chloride (PVC), or Composite material comprising PC, PE, PP and / or PVC and a flame retardant The thermal insulation device according to any one of claims 1 to 7, which is made of

9. The functional filler is at least one of aerogel powder, fumed silica, and glass bubbles; At least one of titanium dioxide (TiO2), iron oxide (Fe2O3), and aluminum oxide (Al2O3), The thermal insulation device of any one of claims 1 to 8, comprising:

10. The functional filler is At least one of magnesium hydroxide (MDH), aluminum hydroxide (ATH), zinc borate, aluminum polyphosphate, and melamine cyanurate The thermal insulation device of claim 9 further comprising:

11. 11. The thermal insulation device according to any one of claims 1 to 10, wherein the polymer layer is mixed with the inorganic fiber layer such that there is no clear boundary between the inorganic fiber layer and the polymer layer.

12. An insulating device according to any preceding claim, wherein two or more layers of film material are attached to one another via an adhesive.

13. 13. The insulation device of any one of claims 1 to 12, wherein the bag includes only three sealed sides, including one linear central seal and two linear side seals, the central linear seal being perpendicular to the two side linear seals.

14. The insulating device of any one of claims 1 to 9, wherein the bag comprises only four sealed sides.

15. An insulating device according to any preceding claim, wherein corners of the bag are folded to prevent the insulating particles from escaping through the corners.

16. 16. The insulation device of any one of claims 1 to 15, wherein the sealed side of the bag is folded and attached to the body of the bag to prevent the functional filler from leaking through the sealed side of the bag.

17. 17. The thermal insulation device of any one of claims 1 to 16, wherein the film material comprises a plurality of perforations, the perforations and the functional filler being sized such that the functional filler does not leak through the perforations.

18. The thermal insulation device of any one of claims 1 to 17, wherein the bag is evacuated to compress the functional filler enclosed within the bag.

19. An insulating device according to any preceding claim, comprising one or more thermally expandable, flame retardant coatings applied to one or two major surfaces of the bag.

20. 20. An insulating device according to any one of the preceding claims, comprising one or more thermally expandable, flame retardant sheets attached to one or two major surfaces of the bag.

21. The thermal insulation device comprises: two of the bags; one or more thermally expandable flame-retardant sheets disposed between the two bags; The thermal insulation device of any one of claims 1 to 20, comprising:

22. 22. The thermal insulation device of claim 20 or 21, wherein the thermally expandable, fire-retardant sheet is a nonwoven glass fiber mat coated or impregnated with a polymeric or inorganic thermally expandable solution.

23. An insulation device according to any preceding claim, comprising a frame structure arranged around the periphery of the insulation device.

24. 24. The thermal insulation device of claim 23, wherein the frame structure is made of silicone.

25. The frame structure is a first frame layer mounted on a first surface of the thermal insulation device; a second frame layer attached to a second side of the insulating device opposite the first side of the insulating device; 25. The thermal insulation device of claim 23 or 24, comprising:

26. 25. An insulating device according to claim 23 or 24, wherein the frame structure is a single piece frame structure.

27. An insulating device according to any one of claims 19 to 26, comprising one or more sheets of electrically insulating film material for sealing one or more respective outer major surfaces of the insulating device.

28. 28. An insulating device according to any one of the preceding claims, comprising tape and / or adhesive applied onto one or more outer surfaces of the insulating device, with a release liner on the tape and / or adhesive to enable the insulating device to be adhered to another object if desired.

29. The thermal insulation device of any one of claims 1 to 28, wherein the functional filler is non-matrix.

30. A battery comprising an insulating device according to any one of claims 1 to 29.

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