Method and system for manufacturing a thermal insulation device

Abstract

A method and system for manufacturing a thermal insulation device, the method including: forming a bag from a film material including perforations; filling the bag with thermal insulating particles having a size that will not pass through the perforations; sealing one or more sides of the bag to prevent the thermal insulating particles from exiting through the one or more sides of the bag; and compressing the bag to remove gas entrapped in the bag after the open side of the bag for filling with the thermal insulating particles is sealed. Optionally, the bag is heated as the bag is compressed, and optionally, the bag is cooled as the bag is compressed.

Description

[Technical Field]

[0001] Field The present invention relates to a method and system for manufacturing a thermal insulation device. The thermal insulation device (or product) may be framed or unframed (frameless). One or more flame-retardant sheets (or layers) and / or coatings may be added to the thermal insulation device to further improve its performance. The thermal insulation device may 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 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 for use in batteries, particularly battery-electric vehicles. This nonwoven 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 compressive properties of the aerogel blanket.

[0003] Existing manufacturing processes for the above-mentioned insulation devices generally involve producing rolls of aerogel blanket using supercritical fluid extraction drying, cutting these rolls into predetermined components, and further transforming the rolls by encapsulating the aerogel blanket components for use in batteries. The process of transforming the aerogel blanket rolls into components adds additional manufacturing costs, which can significantly increase the final price of the product. This can be labor-intensive, result in high scrap rates, and can make it difficult to implement a modern, state-of-the-art quality management system (QMS).

[0004] Another type of thermal insulation device is described in Korean Patent No. 102560566B1. Such a thermal insulation device may include cover layers, which are sealed to contain aerogel powder between the cover layers. The manufacture of such a thermal insulation device is difficult because the aerogel powder is handled. Summary of the Invention [Means for solving the problem]

[0005] overview According to an example of the present disclosure, there is provided a method and a system for manufacturing a thermal insulation device as claimed in the independent claims. Some optional features are defined in the dependent claims.

[0006] 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, given by way of example only and in conjunction with the drawings in which: [Brief explanation of the drawings]

[0007] [Figure 1] 1 illustrates an insulating device according to an example of the present disclosure. [Figure 1A] 1 illustrates a thermal insulation device according to another example of the present disclosure. [Figure 1B] 1 illustrates a film material according to a further example of the present disclosure. [Figure 1C] 1 illustrates a film material according to yet another example of the present disclosure. [Figure 2] 1 illustrates a method for manufacturing a thermal insulation device according to an example of the present disclosure. [Figure 3] 1 shows a large bag used to contain the raw materials. [Figure 3A] 2A and 2B show two examples of injection systems that can be used in the method of manufacturing an insulating device described with reference to FIG. [Figure 3B] 3 shows an example of a mixer that can be used in the manufacturing method shown in FIG. 2. [Figure 3C]1 illustrates an example of an equipment setup for mixing materials to fill an insulation device according to an example of the present disclosure. [Figure 4] 1 illustrates an example of an apparatus for forming, filling, and sealing a bag for an insulation device according to an example of the present disclosure. [Figure 4A] 1 shows an example of a three-sided sealed bag for an insulating device according to an example of the present disclosure. [Figure 5] 5 illustrates examples of the forming, filling and sealing components of the device of FIG. 4. [Figure 6] 1 illustrates a top view of an apparatus for checking the weight of a bag of an insulation device according to an example of the present disclosure. [Figure 6A] 7 shows a front view of the device of FIG. 6. [Figure 6B] 7 shows a perspective view of the device of FIG. 6. [Figure 7] 7 shows a perspective view of a system comprising the device of FIG. 4 and the device of FIG. 6. [Figure 8] 1 shows an example bag of an insulation device according to an example of the present disclosure undergoing a pre-fold (corner folding) process. [Figure 8A] 9 illustrates an apparatus for performing the pre-fold process illustrated by FIG. 8. [Figure 8B] 9 shows an enlarged view of an apparatus for carrying out the pre-folding process illustrated by FIG. 8. [Figure 9] 10 illustrates the application of tape / adhesive at the fold or seal area of ​​an insulating device according to one example of the present disclosure. [Figure 10] 1 illustrates an apparatus for performing a folding process to fold the sealed sides of an insulating device according to an example of the present disclosure. [Figure 10A] 10 illustrates a set of rollers used to fold the sealed sides of an insulation device according to an example of the present disclosure. [Figure 11] 10 illustrates the use of a computer vision system to check the bag length of an insulation device according to an example of the present disclosure. [Figure 11A] 10 illustrates the use of a computer vision system to check the bag height of an insulation device according to an example of the present disclosure. [Figure 12] 1 illustrates an apparatus for degassing, heating, and cooling a bag of an insulating device according to an example of the present disclosure. [Figure 12A] 13 shows several modules that can be installed in the apparatus of FIG. 12 for the purposes of degassing, heating and / or cooling. [Figure 12B] 13 shows side and top views of the device of FIG. 12 with different combinations of modules installed for degassing, heating and / or cooling purposes. [Figure 13] 1 illustrates an apparatus for performing end-of-life (EOL) inspection of a thermal insulation device made according to an example of the present disclosure. [Figure 14] 1 illustrates an example of a computer vision system that can check the taping quality of tape or adhesive applied to a thermal insulation device, according to an example of the present disclosure. [Figure 14A] 10 illustrates four example scenarios of how tape or adhesive can be applied to an insulating device according to one example of the present disclosure. [Figure 15] 1 illustrates a stacking process performed to stack multiple insulation devices according to an example of the present disclosure. [Figure 15A] 16 illustrates a fully stacked bundle of multiple insulation devices of FIG. 15. [Figure 16] 1 shows four examples of compositions comprising a thermal insulation device, a flame retardant device and / or a thermally expandable sheet / coating combination according to one example of the present disclosure. [Figure 16A] 1 illustrates an example of a framed insulation device comprising an insulation device, a flame retardant device, and a frame structure according to an example of the present disclosure. [Figure 16B] 1 illustrates an example of a framed insulation device comprising an insulation device and a frame structure according to an example of the present disclosure. [Figure 16C] 16A and 16B show possible dimensions of the example framed insulation device. [Figure 17] 1 illustrates example steps in a method for manufacturing a framed thermal insulation device as described in examples of the present disclosure. [Figure 18]1 illustrates an example of a film material used to make a thermal insulation device according to an example of the present disclosure. [Figure 18A] 19 shows an example of the film material of FIG. 18 including perforations. [Figure 18B] 1 shows a photograph of an insulating device with four-sided seals according to an example of the present disclosure. [Figure 19] 1 illustrates an apparatus for making a four-sided sealed thermal insulation device according to an example of the present disclosure. [Figure 19A] 1 shows the sealed area dimensions of a four-sided sealed insulation device according to an example of the present disclosure. [Figure 20] 1 illustrates a process for framing an insulating device according to an example of the present disclosure. [Figure 20A] 1 illustrates an adhesive application for attaching a frame to an insulating device according to an example of the present disclosure. [Figure 21] 1 illustrates an apparatus for degassing a framed or frameless insulation device according to an example of the present disclosure. [Figure 21A] 22 shows a bottom perspective view of the top plate of the top conveyor of the apparatus of FIG. 21. [Figure 21B] 22 shows a top perspective view of the upper plate of FIG. 21. [Figure 21C] 21C shows a simplified cross-sectional side view including the upper plate of FIG. 21B, an insulating device according to an example of the present disclosure, and a lower plate of the lower conveyor of the apparatus of FIG. 21 during the degassing process. [Figure 21D] 22 shows an enlarged view of the device of FIG. 21 to highlight the adjustable roller guides. [Figure 21E] 22 shows a side view of the device of FIG. 21 at approximately its full length. [Figure 22] 1 illustrates a process for framing an insulating device according to one example of the present disclosure, with the insertion of a flame retardant device. [Figure 22A] 23 illustrates the sealing process of the framed insulating device resulting from the framing process of FIG. 22. [Figure 22B] 22B shows an apparatus that can be used for the sealing process described with reference to FIG. 22A. [Figure 23]1 shows a checkweigher that can be used for weight checks. [Figure 24] 10 illustrates another framing process for a thermal insulation device according to an example of the present disclosure. [Figure 24A] 25 illustrates another sealing process for the framed insulating device resulting from the framing process of FIG. 24. [Figure 25] 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 25A] 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 25B] 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 25C] 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. DETAILED DESCRIPTION OF THE INVENTION

[0008] 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.

[0009] (A) Thermal insulation device The present disclosure provides a thermal insulation device with a compressible heat shield containing aerogel suitable for use in batteries suitable for electric vehicles (EVs), for example, but not limited to, the thermal insulation device is relatively lightweight in relation to its application in electric vehicle batteries. The term "thermal insulation device" will refer to the thermal insulation device throughout this disclosure.

[0010] Referring to FIG. 1 , one example of a thermal insulation device 100 is a bag (or packet, or sachet, or package, or pouch, or container) filled with aerogel sealed in a “blade” structure. The bag 100 includes three film material layers FML1, FML2, and FML3. The film material layer FML1 is a cover layer, the film material layer FML3 is an inner layer, and the film material layer FML2 is disposed between the film material layers FML1 and FML3. The film material layer FML1 is optional and may serve to protect the thermal insulation device 100 from the external environment. The film material layer FML2 provides heat and flame insulation and mechanical strength as a reinforcing layer for the thermal insulation device 100. The film material layer FML3 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 improves the thermal insulation performance of the thermal insulation device 100 and can maintain a uniform distribution of the functional filler. The film material layer has perforations (or holes, or microperforations, or pores, or openings, or orifices). The average diameter of the perforations (or holes, or pores, or openings, orifices) may be 15 μm or less. The film material layer FML3 and / or one or more other layers may be characterized in that the perforations are sealed when heated and cooled to form during the heating and cooling step described below (see step 232 in FIG. 2). The sides of the film material layer are sealed to form the bag 100 with the functional filler contained therein. The functional filler may comprise insulating particles in nature.

[0011] For example, the first functional filler FF1 may include at least one of aerogel powder, fumed silica, and glass bubbles. The aerogel powder includes fine particles of silica (SiO2) having a diameter of 100 μm or less.

[0012] The second functional filler FF2 may include at least one of titanium dioxide (TiO2), iron oxide (Fe2O3), and aluminum oxide (Al2O3), which serves to improve the thermal insulation performance by suppressing the increase in thermal conductivity of the thermal insulation device even in high-temperature environments.

[0013] The third functional filler FF3 may include at least one of magnesium hydroxide (MDH), aluminum hydroxide (ATH), and zinc borate. When placed 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 slowing the propagation of the flame.

[0014] The fourth functional filler FF4 may be a reinforcing fiber that encapsulates the functional fillers FF1 to FF3 and is adjacent to the film material layer FML3. The functional filler FF4 may include 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 is an optional layer. Because FF4 contacts FF1, FF2, and / or FF3, it can be said to be the innermost layer in this disclosure. If FF4 is not present, FML3 would be such innermost layer.

[0015] In one example, FF1 is a critical component, while FF2 and FF3 are optional and must be uniformly or homogeneously mixed before filling the bag of insulation device 100.

[0016] Table 1 below shows examples of compositions of thermal insulation devices.

[0017] [Table 1]

[0018] In this disclosure, inorganic fibers refer to fibers made from inorganic materials including, individually or in combination, glass, carbon (referring to inorganic types), ceramic, basalt, asbestos, alumina, wollastonite, potassium titanate, and silicon carbide.

[0019] Adhesives may be used between the film material layers that are laminated to form a single sheet. In some instances, due to the high lamination temperatures, the polymer in one film material layer may 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 necessarily be stacked in a clear, orderly fashion, as shown in FIG. 1, and there may be some overlap or intermingling of the layer materials.

[0020] By utilizing woven inorganic fibers, such as E-glass, with extremely low organic binder content (0.05% to 1% by weight) as a film material or filler component, 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.

[0021] In the above-mentioned example compositions and structures in Table 1 above, the typical installation density of the thermal insulation device in the battery module assembly under pressure is 0.2 to 0.5 g / cm 3 In a relaxed state with no applied pressure, the apparent density of the insulating device is 0.05 to 0.4 g / cm 3 is.

[0022] The thermal insulation device 100 may be made, for example, by the following simplified outline of a manufacturing process. 1. Mix functional fillers FF1, FF2 and FF3 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. A heat / pressure sensitive adhesive may or may not be used between the layers. A roll-to-roll thermal lamination process 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 the film material layer FML3, a bag-like structure having one opening is formed with the film material layer FML1 as the outermost surface. 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 so that functional filler 4 surrounds 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.

[0023] Some examples of the thermal insulation device 100 are as follows:

[0024] Referring to FIG. 1A, an example of an insulation device 100 may have a film structure including an optional outer layer 102 (e.g., corresponding to FML1, for protection from external environmental conditions), an intermediate layer 104 (e.g., corresponding to FML2, for enhanced mechanical strength and protection against heat and flame), and an inner layer 106 (e.g., corresponding to FML3, for fixing the distribution of the filler within the cavity and maintaining the shape of the bag).

[0025] 1B shows a second example film structure of thermal insulation device 100, including a first polymer layer 114 (corresponding to FML1) as an outer layer, an inorganic film layer 116 (corresponding to FML2) as a middle layer, and a second polymer layer 118 (corresponding to FML3) as an inner layer. Layers 114, 116, and 118 are bonded together via adhesive 122.

[0026] 1C shows a film structure of a third example thermal insulation device 100, including an inorganic film 124 (corresponding to FML2) as an outer layer and a second polymer layer 126 (corresponding to FML3) as an inner layer. The polymer layer 126 is partially melted and mixed or infiltrated 124 into the inorganic film layer. Such melting, mixing, and infiltration may be achieved, for example, by a thermal lamination process. Notably, there is no clear boundary between the inorganic film layer 124 and the second polymer layer 126.

[0027] 1A, 1B, and 1C, two pieces of the film structure can be placed on either side, joined and sealed at the side edges, and then filled with a filler using a machine or device described below to form a bag. The filler can be an aerogel-based material, i.e., a free-flowing filler 108 such as FF1, and can contain additives such as FF2 and / or FF3. The filler is free-flowing, for example, in powder form. A plurality of holes or perforations 112 (see FIG. 1A) can be provided on the film structure of all three examples for ventilation and / or degassing purposes.

[0028] In another example, film material layer FML2 in FIG. 1, intermediate layer 104 in FIG. 1A, inorganic film layer 116 in FIG. 1B, and inorganic film layer 124 in FIG. 1C may specifically be an E-glass fiber woven textile or fabric.

[0029] Other examples of fully formed and quality inspected insulating devices are 1500 of FIG. 15, 1608 of FIGS. 16-16B, 1800 of FIGS. 18 and 18A, 1804 of FIG. 18B, 1900 of FIG. 19A, 2004 of FIG. 20, 2200 of FIG. 22, 2400 of FIG. 24, 2500 of FIG. 25, 2510 of FIG. 25, 2520 of FIG. 25, and 2530 of FIG. 25.

[0030] Another example of an insulating device is a functional filler (e.g., FF1, FF2, and / or FF3) enclosed in a bag, the bag containing at least: an inorganic fiber layer (e.g., FML2 102); A polymer layer (e.g., FML3 103) and The bag may include a functional filler made from a film material (e.g., a combination of FF4, FML1 to FML3) including: an inorganic fiber layer layered on top of a 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; and the functional filler includes insulating particles in powder form (e.g., FF1). Referring to Table 1, other combinations of inorganic fiber layers layered on top of a polymer layer include: a) FML1, FML2 or FML3 as a polymer layer in contact with FF4 as an inorganic fiber layer; b) FML1 or FML2 as an inorganic fiber layer in contact with FML2 or FML1 as a polymer layer, respectively; c) FML1 as an inorganic fiber layer in contact with FML3 as a polymer layer (in this case, FML2 is absent) etc.

[0031] In this instance, "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. The inorganic fiber layer is preferably woven. The functional filler is also preferably non-matrix, meaning that there is no network formation, no crosslinking with the binder, and / or no structural reinforcing material present in the functional filler. In this case, the functional filler differs from the aerogel blanket discussed in the background section of this disclosure.

[0032] All examples of insulation devices described in this disclosure may be used for framed insulation devices and their combinations with other products described below (e.g., flame retardant products referred to as "flame retardant devices").

[0033] (B) Flame-retardant device In this disclosure, the flame-retardant device refers to, but is not limited to, a thermally expansive sheet suitable for managing thermal runaway 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 (hereinafter, "impregnation liquid"). The impregnation liquid may be a water-based thermally expansive coating containing 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 the FR device 1602 in FIGS. 16 and 16A. The thermally expansive sheet 1612 in FIG. 16 may also be this flame-retardant device. The term "flame-retardant device" refers to the flame-retardant device throughout this disclosure.

[0034] The composition of the thermally expandable sheet (after drying) and the composition of the impregnation liquid for an example of a flame-retardant device will be described below.

[0035] The thermally expandable sheet may include a nonwoven inorganic fiber mat (or fabric), such as ECR-50 (a type of E-glass) manufactured by Owen's Corning. The impregnation solution 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 solution to improve the mechanical robustness, insulating properties, and flame retardancy of the charcoal.

[0036] Tables 1a and 1b below show examples of the composition of the flame retardant device after drying and the composition of the impregnation liquid. Table 2 below shows selected properties of the thermally expandable sheet.

[0037] [Table 2]

[0038] [Table 3]

[0039] [Table 4]

[0040] 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% by weight of the impregnation solution, while a preferred amount is 0.2 to 1.2% by weight of the thermally expandable sheet.

[0041] 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 most preferred. The fiber diameter and length should be 10-15 μm and 15-60 mm, respectively.

[0042] 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 metal oxides, metal hydroxides, metal carbonates, metal silicates, and / or metal powder combinations, can also be used.

[0043] In addition to the above components, optionally, 1 to 10 wt. % of an opacifier such as iron oxide, silicon carbide, and / or titania can be added to the thermally expandable sheet. The opacifier provides high-temperature insulation and serves to reflect and thereby reduce heat transfer via radiation at high temperatures.

[0044] 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.

[0045] 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 finally stirring and mixing the solution containing all the added components for an additional 2 to 3 hours. The curing agent is the last component added to the impregnation solution, just before impregnating the nonwoven inorganic fiber mat. The viscosity is preferably 200 to 500 centipoise (cps).

[0046] The hardener is preferably sodium fluorosilicate or potassium methyl siliconate (most preferred).

[0047] When opacifier, hardener and water are added, the composition of the impregnation liquid is that in Table 3 below.

[0048] [Table 5]

[0049] 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).

[0050] 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.

[0051] 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 the increase can be adjusted by adding colloidal silica.

[0052] (C) Manufacturing process of the thermal insulation device As previously mentioned, the insulating device is essentially a bag (also called a package, pouch, or container) containing insulating particles, including particles in powder form. The insulating particles can include, for example, silica aerogel microparticles and metal oxides as opacifiers. Further examples of insulating device film material layers (FML1-FML3 and FF4) and insulating particles (FF1-FF3) are provided in Table 1 above and later in this disclosure. The insulating particles are packed into the bag and sealed. The bags can be made from custom-designed films made of polymer and glass fabric. These bags can be deaired and compressed to a desired density to form a compressible, super-insulating insulating device. The bags are preferably angular or rectangular in shape and can be sealed on three or four sides. Other shapes are possible, depending on the bag's application. Such an insulating device can be optimized for use as an insulating cell spacer in lithium-ion batteries typically used in electric vehicles.

[0053] The manufacturing process for the thermal insulating device is outlined below.

[0054] In step 202, raw materials are received and verified to ensure the correct materials and quantities are received.

[0055] In step 204, the raw materials are stored in a raw materials warehouse.

[0056] In step 206, 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 can be hoppers. Each mixing buffer can accommodate a different type of powder. For example, one mixing buffer can hold silica aerogel particulates, and another can hold metal oxide (opacifier) ​​powder. If other materials are added, additional mixing buffers can hold them. The mixing buffers can be bowl- or funnel-shaped components with a large receiving area and sufficient depth or height to hold the powder.

[0057] In step 208, powder is dosed or dispensed into the mixer from one or more mixing buffers.

[0058] In step 210, the mixer mixes the powders that have been introduced or dispensed into the mixer for mixing. A mixer agitator or other suitable equipment can be provided to homogenously mix the dispensed powders.

[0059] In step 212, the blend quality is checked. For example, computer vision or X-ray can be used to detect whether the blended powder is sufficiently homogeneous.

[0060] In step 214, the mixed powder that passes the quality check is dispensed or transported to a mixed powder buffer or reservoir.

[0061] Steps 206-214 may be performed on-site as part of a continuous process with steps 216-220, or may be performed at a separate location, in which case the mixed powder produced must be transported to the location where steps 216-220 are performed.

[0062] In step 216, the mixed powder obtained after step 214 is conveyed or poured into a filling hopper that fills the powder into a bag. The filling hopper is attached to a device or machine and configured to supply the mixed powder to the device.

[0063] In step 218, 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. After step 218, 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 on 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 pre-fabricated and provided in a bulk roll for bag formation. The perforations must be small enough to prevent powder from leaking through the perforations.

[0064] In step 220, a quality check is performed on the filling. This is done through a weight check. Each bag is weighed to ensure it meets the predetermined weight requirement. Bags that do not meet the weight requirement are rejected and stored in a rejected product bin. 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 220, the formed bag will have three or four sides with folds formed by the side seals performed by the apparatus in step 218.

[0065] In step 222, a first cleaning step is performed to clean each bag that passed the quality check in step 220. After cleaning, an optional quality check is performed on each bag for cleanliness. Cleaning can be performed via 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 through other suitable cleaning methods. This first cleaning step is useful, for example, if the filling hopper or device has a powder leak (or spill) that causes a bag to burst or leak in steps 218 or 220. Step 222 is optional, but recommended.

[0066] In step 224, 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 224 is optional, but recommended.

[0067] In step 226, after the pre-fold is made, or if the pre-fold is skipped, the folds are turned or folded over and adhesive or tape is applied to the folds of the bag in preparation for attaching them to the body of the bag.

[0068] Step 228 involves folding or tucking the flap of each bag and affixing the flap to the body of the bag. This folding step helps to keep the flap out of the way of assembly of the bag in another product, such as an electric vehicle battery. The flap also provides a containment of the powder at the flap fold line, which helps prevent 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 time.

[0069] In step 230, a quality check for aliasing is performed, which can use computer vision techniques.

[0070] In step 231, leveling of each bag is performed to ensure uniform distribution of the powder inside the bag. For example, this can be done by vibration. This step can be performed independently before degassing or can be combined with the degassing process described below.

[0071] In step 232, each folded bag is transported to a station that 1) evacuates, 2) heats, and 3) cools the bag. These three steps can be performed as follows: During evacuating, the bag is compressed to force air out of the bag. Such evacuating 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, during which, for example, the film layer softens and forms the bag, which helps release more gas from the bag. After heating, the bag is cooled. The cooling can be active, in which the temperature is actively reduced to rapidly cool the bag. Alternatively, cooling can occur naturally. Preferably, the bag is under compression throughout the three steps.

[0072] In step 234, a second cleaning step is performed to clean each bag evacuated in step 232. After cleaning, an optional cleaning quality check can also be performed. Cleaning can be performed via air purging, i.e., air is blown onto the bag to clean it, and / or via vacuum suction, where powder (if present) is sucked from the bag, and / or through 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 232. Step 234 is optional, but recommended.

[0073] In step 236, each bag must undergo an optional but recommended final inspection (quality check). 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 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.

[0074] In step 238, an optional taping step of the bag can be performed to provide the bag with tape that 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.

[0075] In step 240, the quality of the taping performed in step 238 is checked to ensure proper application of the taping and / or release liner. This check can be performed using computer vision techniques.

[0076] In step 242, the bags are packaged and prepared for delivery. For example, this may be done by first stacking and tying the bags into bundles, which are then packed into cardboard boxes.

[0077] In step 244, the bag-filled cardboard boxes are stacked on a pallet.

[0078] In step 246, the pallet is transferred to a pre-shipment warehouse and prepared for shipping.

[0079] Generally, the key components of the manufacturing process described above are forming the bag and filling it with powder, folding the sealed sides of the bag, degassing, and heat treating.

[0080] An example of steps 206-214 relating to powder mixing is described in detail below.

[0081] In one example, the raw materials required for the mixing process include aerogel particles in powder form and iron oxide particles in powder form.

[0082] The raw materials can be fed in different ways. One possibility is feeding in large or jumbo bags 300 as shown in FIG. 3. The raw materials are unloaded from such large bags and transferred to a dosing system. A powder conveying system can be used to transport the raw material powder to the dosing system. The powder conveying system can include a vacuum feeder and / or a screw feeder or conveyor for transporting the raw material powder to the dosing system. In the dosing system, there are two or more containers containing different types of raw material powder, i.e., the containers are sorted by material. Each of these containers can be a hopper.

[0083] FIG. 3A shows examples of two types of dosing systems, B and C, that can be used to obtain a desired powder combination before the combined powders are mixed by a mixer. A vacuum feeder can be used to use vacuum suction to suck up powder contained in a big bag 300 and transport the powder to the respective raw material buffers 302 in dosing systems B and C. Alternatively, a screw feeder (e.g., involving the use of an auger screw) or conveyor can be used, or used in conjunction with a vacuum feeder, to transport the powder to the respective raw material buffers 302 in dosing systems B and C. For example, aerogel powder can be transported to hoppers 304a and 304b in dosing systems B and C, respectively. An additive such as iron oxide powder can be transported to hoppers 306a and 306b in dosing systems B and C, respectively. If there are more than two types of powders to combine, more buffer hoppers, such as 304a and 304b, can be used.

[0084] Dosing system B may include a screw feeder (eg, with the use of an auger screw) or a conveyor for dosing powder from buffers 304a and 306a into holding hopper 308a in the desired amount.

[0085] The auger screw is part of a screw or auger conveyor, which is industrial equipment used to transport bulk quantities of particulate solids (e.g., powders, granules, and granules), semi-solids, liquids, and even non-flowable materials from one location to another. Holding hopper 308a is used to distribute the powders from buffers 304a and 306a to the mixer. A larger auger screw can be used to more quickly dispense the larger amount of aerogel powder in each bag of the insulation device, and a smaller auger screw can be used to dispense the smaller amount of iron oxide powder in each bag of the insulation device.

[0086] Examples of the types of mixers used include air mixers, vertical mixers equipped with agitators and choppers, and vacuum mixers. The mixing time depends on the mixing process and the type of mixer. Figure 3B shows an example of a mixer 310. The mixer 310 includes a mixing chamber 1, an agitator 2 that rotates to mix the powders fed into the mixing chamber 1, and an air pump 3 to pump air into the mixer to facilitate the mixing process.

[0087] 3A, similarly, the dosing system C may comprise a screw feeder (e.g., with the use of an auger screw) or conveyor for dosing powder from buffers 306a and 306b into holding hoppers 308a and 308b in desired amounts. Holding hopper 308b is used to distribute the powder dispensed from buffers 304b and 306b to a mixer (e.g., 310 in FIG. 3B).

[0088] Input system B differs from input system C in that input system B adopts synchronous raw material supply, while input system C adopts asynchronous raw material supply.

[0089] Dosing system B includes load cells D (load cells are also referred to as weighing devices or weight sensors in this disclosure) installed in buffers 304a and 306a, respectively, to weigh the contents contained therein. The powder in buffers 304a and 306a is simultaneously (i.e., at the same time) dosing or pouring into hopper 308a. The correct amount of powder dosing is determined by the weight loss of each buffer 304a and 306a. Having holding hopper 308a is optional; powder can be dosing directly into mixing chamber 308a.

[0090] Dosing system C includes a load cell D installed in holding hopper 308b to weigh the contents contained therein. Buffers 304b and 306b do not have a load cell D. In this case, the powder in buffers 304b and 306b is dosing asynchronously (i.e., at different times) into hopper 308b. For example, first, the correct amount of powder is dosing or pouring from one of buffers 304b and 306b into hopper 308b until the desired weight is measured by load cell D in hopper 308b. Second, the correct amount of powder is dosing from the other buffer 306b or 304b into hopper 308b until the desired weight is measured by load cell D in hopper 308b.

[0091] An optional blend quality check may be performed. Such a blend quality check may involve obtaining only a powder sample from the batch of powder mixture discharged from the mixer for checking, or checking all of the blended powders in the batch of powder mixture discharged from the mixer. In the case of a powder sample check, if the powder sample passes the check, the entire batch of powder mixture passes the check. The purpose of the blend quality check may include verifying that the powder composition, particle size distribution, and homogeneity of the powder mixture meet requirements. One or more checks may include, for example, the use of techniques involving scanning electron microscope (SEM) imaging, X-ray systems or laser diffraction (LD), dynamic light scattering (DLS), dynamic image analysis (DIA), and / or sieve analysis. If the quality of all blended powders is checked, those powder mixtures that pass the check and are identified as good are transferred to one or more buffer systems to prepare for further processing. Bad (NG) powders can be transferred to a rework station or rejected and discarded.

[0092] FIG. 3C shows an example of a system architecture for powder mixing, storage, and transfer. This example is described below. Holding hoppers 308a and 308b of input systems B and C, respectively, feed a powder mixture of aerogel particles and iron oxide to mixer 310. If a mix quality check is included, the mix quality check is performed on the powder mixture exiting mixer 310, and good powders that pass the quality check are transferred to one or more buffer systems 316 and / or 318. A buffer system refers to a reservoir (or repository) of the powder mixture. In addition to storage, the buffer system may have an agitator or be configured to blow air to provide continuous agitation of the powder mixture to ensure homogeneity. If a quality check is not included, the mixed powder or powder mixture is transferred to one or more buffer systems 316 and / or 318. The use of at least two buffer systems is preferred because a second or more buffer systems allows for traceability of the mixture by powder batch. That is, each buffer system can be associated with one batch of powder mixture. For greater accountability, it is preferable to manufacture the mixed powder in batches. The contents of each batch of mixed powder can be defined in terms of the buffer volume around the mixer for each buffer system. The mixed powder in each buffer system 316 and 318 can be transferred in batches to the apparatus 400 for bag forming, powder filling, and sealing. The mixed powder can be transferred to the apparatus 400 via a vacuum feeder and / or a screw feeder or conveyor.

[0093] The system of FIG. 3C may include a control station (not shown) with one or more processors or controllers that control the process. The control station may have a display that displays a graphical user interface for user control and configuration. The display may be a touchscreen display. The control station may include indicator lights that indicate whether the system is operating, in various stages of operation, or is not functioning. Multiple user interfaces, such as buttons, knobs, switches, etc., may be provided on the control station to control the system. The system also includes one or more motors or engines and a power source to drive its moving parts.

[0094] Steps 216 and 218 are described in more detail below with reference to the example shown in Figure 4. Figure 4 shows a front perspective view 4A and a rear perspective view 4B of the apparatus 400 of Figure 3C. The apparatus 400 is a vertical fill and seal machine. The apparatus 400 includes one or more motors or engines and a power source for driving its moving parts.

[0095] The key components performed by apparatus 400 are bag forming, powder filling, and bag sealing. When steps 206-214 of FIG. 2 are performed on-site as part of a continuous process with steps 216-220, the inputs to apparatus 400 include, first, mixed powder transferred from the final powder mixing step 214 through powder input point 402 to filling hopper 404, and, second, film material 406 provided from a roll of film. Film material 406 may be prefabricated and have the film structure described above in Table 1 and shown in FIGS. 1A, 1B, and 1C, as well as the examples abbreviated as PET / EG / PE or PET / AL / PE described below. In this example, the output from apparatus 400 is a three-sided sealed bag filled with the mixed powder. In another example, the bag may be a four-sided sealed bag. Forming, filling, and sealing components 408 are fixed within the cabinet of apparatus 400 and are not visible in FIG. 4.

[0096] FIG. 4A shows a back view 4C and a front view 4D of an example bag 410 made by apparatus 400, which is rectangular in shape and has three-sided seals. The three-sided seal includes one vertical or center seal 412 and two side seals, a top seal 414 and a bottom seal 416. The vertical seal 412 is disposed between the two side seals 414 and 416 and is joined to the two side seals 414 and 416 at the ends of the vertical seal 412. The vertical seal 412 can be said to be orthogonal to the two side seals 414 and 416, which are disposed horizontally relative to the bag 410. For example, the seals 412, 414, and 416 of the bag can have a seal width of 10 to 20 mm.

[0097] An overview of how bag 410 is formed is as follows: Film material from a roll of film (i.e., 406 in FIG. 4) is wound to form a tubular structure, and two opposing sides of the film material are joined by sealing vertical seal 412. After vertical seal 412 is sealed, bottom seal 416 is sealed to form a preformed bag with an open top or end. Powder is dispensed or fed into the preformed bag through the open top or end. Once the preformed bag is filled, it is sealed to form top seal 414, closing off the open top or end opening.

[0098] Forming, filling, and sealing components 408 in Figure 4 that perform the respective forming, filling, and sealing processes are combined and performed by one machine, or apparatus 400. Such components 408 are configured to fill a powdered and / or granular product, such as the mixed powder discharged from buffer systems 316 and / or 318 in Figure 3C, into a bag (e.g., 400 in Figure 4).

[0099] Figure 5 shows the form, fill and seal component 408 of Figure 4. Figure 5 shows three views, 5A, 5B and 5C. View 5A shows a first example of the form, fill and seal component 408, view 5B shows a second example of the form, fill and seal component 408, and view 5C shows a bag forming tool 528 comprising a bag forming shoulder 510 and a forming tube 512.

[0100] Specifically, FIG. 5A shows a filling hopper 404, which is a mixed powder supply unit. A forming tube 512 is connected to the filling hopper 404. An auger screw 502 is provided for adding powder, particularly for conveying the mixed powder supplied to the filling hopper 404 into each formed bag. The auger screw 502 extends from a space that holds the mixed powder in the filling hopper 404 through the hollow core of the forming tube 512. One end of the forming tube 512 is connected to the filling hopper 404, and the opposite end of the forming tube 512 is an opening for distributing the mixed powder conveyed by the auger screw 502.

[0101] 4 is in roll form and is supplied by an unwinding device 506 that cooperates with a plurality of cylindrical rods or guide rollers 524 to unwind the film material 406 from the roll and transport the film material 406 to the bag forming shoulder 510. The width of the film roll may define the width of the formed bag.

[0102] In a first step, the film material 406 is folded over a bag-forming shoulder 510, which shapes the flat film material 406 into a cylindrical tube. The cylindrical tube is formed on a forming tube 512, which maintains its tubular shape. A film removal (or take-out) unit is provided below the bag-forming shoulder 510 to pull and remove the film material 406 from the film-forming area. The film removal unit includes a pair of moving devices 516 with endless tracks (or belt straps) positioned adjacent to the sides of the film material 406. Each moving device 516 is driven by a motor to move the endless tracks 516 and pull the film material 406 downward by friction. The endless tracks move synchronously to ensure a uniform pulling effect on the film material 406.

[0103] In a second step, after the tube is formed on the forming tube 512, the ends 526 of the film material 406 are placed adjacent to each other and vertical sealing is performed at the ends 526 using a vertical sealer 514 to form a center seal of the bag (or pouch). The vertical sealer 514 includes a heater for softening the film material 406 so as to allow the ends 526 of the film material 406 to adhere to each other and form the center seal (e.g., 412 in FIG. 4). It is understood that the film material 406 in this example includes one or more layers of material suitable for such a sealing process. It is believed that powder distributed within the forming bag will not leak through the center seal.

[0104] In the third step, horizontal sealing is performed using a horizontal sealer 518 to seal the bottom end 530 of the bag (or preformed bag) 532 to be formed. The horizontal sealer 518 has a pair of sealing jaws for pressing two layers of film material 406 together to form a cylindrical tube. The horizontal sealer 514 has heater elements in one or two of the sealing jaws that melt or soften the film material 406 when the jaws press against the two layers of film material 406. The melting or softening of the two layers of film material 406 causes them to adhere to each other, forming a bottom seal (e.g., 416 in FIG. 4 ) at the bottom end 530 of the preformed bag. It is believed that powder dispensed into the bag will not leak out of the bottom end 530 after such sealing. Sealing the bottom end 530 of the preformed bag 532 also seals the top end of the previously filled bag 522.

[0105] After the bottom end 530 is sealed, in the fourth step, the mixed powder in the filling hopper 404 is dosed or distributed into the preformed bag 532 by the auger screw 502 to a predetermined amount. The precise dose is defined by the rotation speed and travel speed of the auger screw 502.

[0106] When a predetermined amount of mixed powder has been filled into the preformed bag 532, in the fifth step, the film material 406 moves downward and the vertical sealer 518 performs horizontal sealing to seal the top end of the preformed bag 532. By sealing the top end of the preformed bag 532, the bottom end of the next bag to be filled is also sealed.

[0107] In a sixth step, filled bags, such as bag 522 sealed at the top by a transverse seal, are cut from the film material.

[0108] The second example shown by FIG. 5B functions similarly and has the same elements sharing the same reference numbers as the first example of FIG. 5A. The only difference is in the way the powder is loaded or dispensed into the preformed bag 532. Instead of an auger screw 502, the mixed powder is dispensed by allowing the powder to fall by gravity from the fill hopper 404 into the preformed bag 532. FIG. 5B also more clearly shows the same elements present in FIG. 5A.

[0109] During the six steps described above, the length of the film material may be measured or determined using computer vision to detect markings printed on the film material 406. For example, the length of the final formed bag may be defined by printed marks printed on the film material 406. The length of the film material may be measured or determined using an encoder, which provides motion feedback for linear measurement by generating pulses in response to the linear displacement of the film material being measured. Such an encoder then transmits those pulses to a controller, which converts those pulses into distance. A measuring wheel may be used in conjunction with such an encoder.

[0110] Exemplary machine parameters for device 400 are shown in Table 4 below.

[0111] [Table 6]

[0112] The apparatus 400 includes a control station (not shown) with one or more processors or controllers that control the molding, filling, and sealing processes. The control station may have a display that displays a graphical user interface for user control and configuration. The display may be a touchscreen display. The control station may include indicator lights that indicate whether the apparatus 400 is operating, in various stages of operation, or is non-functional. Multiple user interfaces, such as buttons, knobs, switches, etc., may be provided on the control station for controlling the apparatus 400.

[0113] After the bag containing the mixed powder is formed, an optional but recommended fill quality check (corresponding to step 220 in FIG. 2) can be performed. This check ensures the accuracy of the bag filling process and should measure the weight of the powder dispensed immediately after the bag filling process is complete.

[0114] The input for the fill quality check is filled and sealed bags from the bag form, fill, and seal process. The weight of each filled bag is measured. No good (NG) bags, which are filled bags that do not meet predetermined weight requirements, are rejected. NG bags can be rejected by being transferred to a reject bin. Good bags that meet the predetermined weight requirements are transferred downstream for further processing.

[0115] An example of an apparatus 600 for performing a fill quality check is shown in Figures 6, 6A, and 6B. Figure 6 shows a top view of the apparatus 600, Figure 6A shows a front view of the apparatus 600, and Figure 6B shows a perspective view of the apparatus 600. Referring to Figures 6, 6A, and 6B, the apparatus 600 may be a checkweigher with a conveyor system that moves filled bags to different sections of the apparatus 600 for performing different tasks. The arrows in Figures 6, 6A, and 6B indicate the direction of bag transport.

[0116] The apparatus 600 includes a control station 604 with one or more processors or controllers that control the fill quality check process. The control station 604 may have a display 620 that displays a graphical user interface for user control and configuration. The display 620 may be a touchscreen display. The control station 604 may include an indicator light 616 that indicates whether the apparatus 600 is operating or not. Multiple user interfaces, such as buttons, knobs, switches, etc., may be provided on the control station 604 for controlling the apparatus 600. The apparatus 600 includes one or more motors or engines and a power source for driving its moving parts.

[0117] Apparatus 600 includes a feed conveyor section 606 that receives filled bags from an upstream process, such as apparatus 400 of FIG. 4 (i.e., a bag form, fill, and seal machine). Moving downstream, apparatus 600 includes one or more weigh conveyor sections, such as 608 and 610, that include load cells that weigh filled bags placed thereon. Each weigh conveyor section can be configured to weigh a range of bag sizes. For example, weigh conveyor section 608 can weigh small, lightweight bags, while weigh conveyor section 610 can weigh large, heavy bags. Bags of different sizes can be made in different batches. For a batch of larger bags, weigh conveyor section 608 can be stopped, and weigh conveyor section 610 is activated to weigh the larger bags. The same can be done for smaller size bags, but weigh conveyor section 608 is activated and weigh conveyor section 610 is deactivated.

[0118] The apparatus 600 also includes a discharge conveyor section 614, which is a reject station that either rejects bad (NG) bags that fail predetermined weight requirements by transferring them to a reject bin 622, or transfers good bags that pass predetermined weight requirements downstream for further processing. Transfer of the NG bags to the reject bin 622 may be accomplished by an air purge using air to blow the NG bags into the reject bin 622, by using a mechanical push flap or other pushing mechanism to push the NG bags into the reject bin 622, or by other suitable means. The reject bin 622 may be locked to prevent mishandling of rejected bags.

[0119] Apparatus 600 may include feedback control for cooperation with apparatus 400 of FIG. 4. The weight requirement may be an acceptable weight range for a particular bag size. If the bag weight appears to be approaching or exceeding a tolerance or limit of the acceptable weight range, a feedback data signal may be electronically communicated to apparatus 400 of FIG. 4 to adjust the powder dosage. Apparatus 400 then automatically increases or decreases the amount of powder dosage filled into each bag.

[0120] An optional step of a sealing quality check may be included immediately after or immediately before the fill quality check (corresponding to step 220 in FIG. 2 ). The input for the sealing quality check is the filled, sealed bags from apparatus 400 in FIG. 4 . The sealing quality check may be performed using computer vision techniques to check that each bag is properly sealed and whether powder is present around or within the sealed area being checked. FIG. 4A shows the sealed areas corresponding to center seal 412, top seal 414, and bottom seal 416 that may be checked. For example, a computer vision system with a backlight may be used. Bad (NG) bags that are not properly sealed and / or have powder present around or within the sealed area are rejected and transferred to a reject bin. Good bags that meet the requirements are transferred to the next process.

[0121] After the fill quality check or seal quality check, a first cleaning process (corresponding to step 222 in FIG. 2) can be performed to ensure that the surfaces of the filled bags are clean. The main purpose is to clean the surface of each bag, especially the horizontal sealing area (i.e., top seal 414 and bottom seal 416 in FIG. 4A).

[0122] The input for the first cleaning process is good bags from the filling quality check or the sealing quality check. The good bags are cleaned first. The cleaning process can be divided into several steps, such as cleaning with a rotating air nozzle that blows air onto the surface of each bag, followed by cleaning with a brush that brushes the surface of each bag. The surface can include a horizontal sealing area and a vertical sealing area (i.e., the center seal 412 in FIG. 4A).

[0123] A cleaning device including the air nozzles and / or brushes can be used for the first cleaning process. The device may include a control station including one or more processors or controllers for controlling the process. The control station may have a display that displays a graphical user interface for user control and configuration. The display may be a touchscreen display. The control station may include indicator lights that indicate whether the device is operating, in various stages of operation, or is non-functional. The control station may include multiple user interfaces, such as buttons, knobs, switches, etc., for controlling the device. The device includes one or more motors or engines and a power source for driving its moving parts.

[0124] After cleaning, each bag can be checked for cleanliness. Cleaning results can be verified using ultraviolet light, x-ray, or sensitive camera systems. Defective bags that are not properly cleaned can be rejected and sent to a reject bin. Good bags with a high cleanliness are sent to the next process.

[0125] FIG. 7 shows an example of a combined or integrated system comprising components of the bag forming, filling, and sealing process, i.e., apparatus 400 of FIG. 4, and a fill quality check station, i.e., apparatus 600. Positions X and Y marked in FIG. 7 are possible locations for installing one station for the aforementioned sealing quality check. A conveyor 702 is provided between apparatus 400 and apparatus 600 to transfer filled bags from apparatus 400 to apparatus 600 for the fill quality check. FIG. 7 shows a vacuum feeder, not shown in FIG. 4, installed in apparatus 400 for feeding mixed powder from the mixing process described with reference to FIG. 3C. The direction of bag transport is indicated by arrows in FIG. 7. Instead of having separate control stations for apparatus 600 and apparatus 400, there can be a common control station that controls both apparatuses.

[0126] After the bags are cleaned, an optional but recommended pre-folding (or corner folding) process begins (corresponding to step 224 in FIG. 2). The primary purpose of this pre-folding process is to prevent powder leakage through the sealed corners of each bag. The bags will undergo compression and heat treatment at a later stage, which could cause the sealed sides or edges of the bag to break, resulting in powder leakage or, even worse, causing the bag to burst. The input to this pre-folding process is cleaned bags that have passed the cleanliness check from the first cleaning process.

[0127] FIG. 8 shows a back view 8A of a bag 808 having a center seal 806, with the corners of the bag 808 about to be folded. FIG. 8 also shows a front view 8B of the bag 808 with the folded corners 804 secured in place. The pre-folding process involves aligning each bag 808 in position for folding its corners, defining a fold line 802 at each corner for folding the corner, folding or otherwise crimping the corners of the bag 808 in a manner indicated by the arrows in FIG. 8, and applying pressure to secure the corners in the folded configuration to form the folded corners 804. The product of the pre-folding process is a pre-folded (or corner-folded) bag, which looks like the bag 808 in front view 8B.

[0128] FIG. 8A shows an example of an apparatus 800 for performing the pre-folding process. The apparatus 800 includes one or more motors or engines and a power source for driving its moving parts. In this example, the bag whose corners are to be folded is rectangular in shape. FIG. 8B shows several close-up views of a four-corner folding device 810 used to fold the four corners of the bag. Referring to both FIGS. 8A and 8B, the apparatus 800 includes a raised platform 822 mounted on top of a table 818. The four-corner folding devices 810 are mounted at the four corners of the raised platform 822. The raised platform has a recessed portion 824, which has a depth H and has walls such as walls P, Q, and R, as demarcated in FIG. 8B. Wall P is located at a position corresponding to a corner position of the bag and is configured to be angled relative to walls Q and R to facilitate corner folding of the bag. Walls similar to wall P are provided at the other corners of the recessed portion 824 to facilitate corner folding of the bag.

[0129] The apparatus 800 includes a folding fixture 812 on which the bag rests before the corners are folded. The folding fixture 812 is configured to rise and fall in a recessed portion 824. The bag must be aligned and positioned on the folding fixture 812 so that its corners can be folded. The folding fixture 812 can be sized to closely match the size of the bag or have a bag holding area sized to closely match the bag so that the bag is aligned when it is detected that it is installed in the folding fixture. This can be done using a computer vision system. The bag can be held in place before the corners are folded by vacuum suction. Vacuum suction can be applied to hold the folding fixture 812 in place with the bag aligned. The folding fixture 812 can also have a vacuum suction opening to suck the bag and hold or secure it in place on the folding fixture 812. Table 818 can be equipped with a vacuum suction system that includes one or more holes for vacuum suction to act on folding fixture 812 and / or the aligned bag. In another example, the bag can be picked up, aligned, and placed in the correct position in folding fixture 812 by a pick-and-place device (or robotic arm) using vacuum suction.

[0130] Each corner folding device 810 includes a sliding cylinder 816 connected to a folding fixture 814. A linear motor or actuator is used to drive the movement of the sliding cylinder 816. The folding fixture 814 is shaped to fold the corner of the bag and may have, for example, beveled edges to facilitate folding. As previously described, the folding fixture 812 is configured to rise and fall within the recessed portion 824. When a bag is secured in place on the folding fixture 812 and the folding fixture 812 is not yet lowered into the recessed portion 824, vertical downward movement of the folding fixture 812, which lowers the folding fixture 812 into the recessed portion 824, causes the corner of the bag to contact an angled wall within the recessed portion 824, such as wall P, which is configured to fold or bend the corner of the bag. Using a wall such as wall P, the folding fixture 812 moves vertically downward into the recess to pre-fold the corners of the bag to an approximately 90-degree angle. When the bag is in the pre-folded position, the sliding cylinder of the four-corner folding device 810 moves forward along with each folding fixture 814 to further fold the approximately 90-degree corners to an approximately 180-degree angle. Each corner folding device 810 also includes a heating element mounted on the folding fixture 814 to apply heat to the folded corners. The heating element softens the folded film material to ensure that the folded corners remain in the folded configuration. After the corner folding process is completed, the sliding cylinder 816 returns to its home position, and the pre-folded bag with folded corners can be removed from the folding fixture 812 and transported to the next process.

[0131] The apparatus 800 may include a control station (not shown) with one or more processors or controllers that control the process. The control station may have a display that displays a graphical user interface for user control and configuration. The display may be a touchscreen display. The control station may include indicator lights that indicate whether the apparatus 800 is operating, in various stages of operation, or is non-functional. The control station may include multiple user interfaces, such as buttons, knobs, switches, etc., for controlling the apparatus 800.

[0132] After the pre-folding process, a tape and / or adhesive application process (corresponding to step 226 in FIG. 2) begins. Such a tape / adhesive application process may be performed before or after the pre-folding process. The primary purpose of this tape / adhesive application process is to allow the end flaps of the pre-folded bag with top and bottom seals to be glued and secured in place for subsequent further folding or folding processes.

[0133] FIG. 9 shows a front view 9A and a side view 9B of a pre-folded (corner-folded) bag 900. The inputs to the tape / adhesive application process are tape / adhesive 902 and a pre-folded (corner-folded) bag, such as the bag 900 shown in FIG. 9, or a cleaned bag if the pre-folding process was skipped. The tape / adhesive application process involves aligning and positioning the bag 900 for tape / adhesive application and cutting and applying the tape or adhesive 902 to the sealing area at the fold (or sealed side) of the bag, specifically onto the bag's top sealing area 904 or bottom sealing area 906, also referred to as the bag's side sealing area. The product of the tape / adhesive application process is a bag with tape or adhesive applied to the bag fold or top and bottom bag sealing areas. For example, double-sided tape (or transfer tape or double-sided adhesive-coated tape) can be applied to the bag fold. In another example, adhesive (hot melt adhesive) can be applied to the fold. If double sided tape or transfer tape is applied, a tape applicator 908 is used to ensure the required tape length and repeatability of application. If an adhesive such as a hot melt adhesive is used, a dispensing device 908 is used to dispense a predetermined amount of adhesive onto the fold.

[0134] After applying the tape / adhesive to the horizontal seal area of ​​the bag, a folding process (corresponding to step 228 in FIG. 2 ) is performed to fold or fold the horizontal seal area over and under the tape / adhesive so that the tape / adhesive adheres 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 later in the process, the folded or folded seal will be more firmly pressed against the body of the bag, and therefore the sealed side or edge of the bag is less susceptible to opening and spilling the filled contents. The input to this folding process is a corner-folded bag with adhesive / tape applied to the horizontal seal area or a cleaned bag with adhesive / tape applied to the horizontal seal area if the pre-fold (corner folding) process was skipped. The folding process involves defining a fold line, folding the fold of the bag toward the front or back side of the bag at an angle of approximately 180 degrees, and securing the folded fold to the body of the bag by gluing. The product of the folding process is a bag with folded (or folded) sides.

[0135] FIG. 10 shows an example perspective view 10A of an apparatus 1000 for performing the folding process. The apparatus 1000 includes two rows of rollers 1002 and 1004 arranged to fold or fold over the top and bottom sealed sides, respectively, of each bag fed into the apparatus 1000. By moving the bag through the two rows of rollers 1002 and 1004, both sealed sides of the bag (i.e., the top and bottom sealed sides) are simultaneously folded and bonded. FIG. 10 also shows a side view 10B of the row of rollers 1002 and a top view of the row of rollers 1002. Each row of rollers 1002 and 1004 includes multiple groups of roller sets. In this example, row 1002 has three roller groups: a first roller group, a second roller group, and a third roller group, which are demarcated in top view 10C. The first group of rollers is used to define the fold line of the top sealed side (or top cuff) of the bag, which will be folded or folded over. The second group of rollers is used to fold the top sealed side of the bag from 0 to 180 degrees. The third group of rollers is used to adhere, secure, or lock the portion of the top sealed side that has the tape / adhesive applied to it to the body of the bag. The row of rollers 1004 is used to fold and adhere the bottom sealed side (or bottom cuff) and is configured similarly to the row of rollers 1002. Note that the terms top and bottom of the bag are interchangeable, as the bag is symmetrical along an axis that cuts through the center of the bag and is parallel to the horizontal sealed side of the bag.

[0136] The apparatus 1000 may include a control station (not shown) with one or more processors or controllers that control the process. The control station may have a display that displays a graphical user interface for user control and configuration. The display may be a touchscreen display. The control station may include indicator lights that indicate whether the apparatus 1000 is operating, in various stages of operation, or is non-functional. Multiple user interfaces, such as buttons, knobs, switches, etc., may be provided on the control station for controlling the apparatus 1000. The apparatus 1000 includes one or more motors or engines and a power source for driving its moving parts.

[0137] The apparatus 1000 includes a conveying apparatus 1001 having one or more movable fixtures 1006 positioned between a row of rollers 1002 and a row of rollers 1004, for moving a bag through the row of rollers 1002. FIG. 10 illustrates one such fixture 1006. The one or more fixtures 1006 are attached to and slidable along a pair of rails 1008. In the case of two or more fixtures 1006, they may be positioned adjacent to one another. A suitable motor or actuator is used to move the one or more fixtures 1006. Each fixture 1006 is used to hold a bag having a sealed side so that it is folded or folded in place. The bag can be mechanically clamped using a clamp to secure the bag to each fixture, or vacuum suction can be used to secure the bag to each fixture. Parallel pressure from top to bottom can be applied to the bag by the clamp or using vacuum suction. The bag must be secured within fixture 1006, and the sealed side of the bag must be aligned to interact with roller groups 1, 2, and 3 of the two rows of rollers 1002 and 1004. The sealed side of the bag is then folded and adhered to the body of the bag by moving fixture 1006 carrying the bag through the first, second, and third roller groups of the two rows of rollers 1002 and 1004. The bag is preferably moved at a constant speed through the first, second, and third roller groups of the two rows 1002 and 1004.

[0138] A vacuum conveyor may be used for continuous processing, which involves moving multiple bags through all roller groups 1, 2, and 3 to fold the folded portions. A vacuum conveyor refers to a suction device that uses air or reduced pressure to hold the bags in place. When a vacuum conveyor is used, each bag may be positioned on a vacuum fixture. The vacuum fixture may use vacuum suction to hold the bags. Multiple such vacuum fixtures may be positioned adjacent to each other. In another example, the vacuum conveyor may include a perforated, movable, endless belt. Bags with sealed sides to be folded are sequentially placed on the belt as the belt is driven by a drive such as a motor or engine. The perforations in the belt are fluidly connected to a vacuum suction unit. When the vacuum suction unit is activated, the bags placed on the moving endless belt are attached to the endless belt by the suction force provided through the perforations. The folding process ends when the bags reach the end of the row of rollers 1002 and 1004.

[0139] The rollers in each of the first, second, and third roller groups are configured differently. FIG. 10A shows a simplified cross-sectional side view of one roller set 1012 (marked "1") in the first roller group and six rollers 1014, 1016, 1018, 1020, 1022, and 1024 (marked "2" through "7") in the second roller group. Each roller set in the third roller group is configured similarly to roller set 1024 in the second roller group. FIG. 10A also shows a bag 1010 having an unfolded or unfolded sealed side 1026 that will be folded. Each roller set includes an upper roller that works on the upward-facing surface of the bag 1010 or the upward-facing surface of the sealed side 1026 to be folded, and a lower roller that supports the downward-facing surface of the bag 1010 or the downward-facing surface of the sealed side 1026. 10A shows various stages of folding the sealed side 1026 of the bag 1010. The rollers in each row 1002 and 1004 are driven, for example, by a belt or chain. The rollers in each row 1002 and 1004 can be configured to move, and the speed of the roller movement can be adjusted. The rollers in the two rows 1002 and 1004 should move synchronously to ensure uniform folding of the sealed side 1026.

[0140] Specifically, in this example, roller set 1012 has an upper roller 1i with a ring of prongs 1012a and a lower roller 1ii with corresponding ring grooves for receiving the prongs 1012a. The prongs 1012a and corresponding ring grooves are used to form fold lines on the sealed side 1026 of the bag 1010 as the sealed side 1026 moves past roller set 1012.

[0141] The roller set 1014 has an upper roller 2i that presses the body of the bag 1010 against the flat surface of the lower roller 2ii of the roller set 1014 to support the bag 1010 between the upper roller 2i and the lower roller 2ii. The lower roller 2ii is configured to have a gentle slope (e.g., angled at 45 degrees or less with respect to a horizontal axis) to induce the sealed side 1026 to fold at a gentle angle along a fold line as the sealed side 1026 moves past the roller set 1014.

[0142] The roller set 1016 has an upper roller 3i that presses the body of the bag 1010 against the flat surface of a lower roller 3ii of the roller set 1016 to support the bag 1010 between the upper roller 3i and the lower roller 3ii. The lower roller 3ii is configured to have a steep slope (e.g., angled greater than 45 degrees but less than 90 degrees relative to the horizontal axis) to induce the sealed side 1026 to fold at a steep angle along a fold line as the sealed side 1026 moves past the roller set 1016.

[0143] The roller set 1018 has an upper roller 4i that presses the body of the bag 1010 against the flat surface of the lower roller 4ii of the roller set 1018 to support the bag 1010 between the upper roller 4i and the lower roller 4ii. The lower roller 4ii is configured with a right-angle slope (i.e., 90 degrees relative to the horizontal axis) to induce the sealed side 1026 to fold at 90 degrees (relative to the horizontal axis) as the sealed side 1026 moves past the roller set 1014.

[0144] The roller set 1020 has an upper roller 5i configured with a gentle slope to guide the sealed side 1026, which is folded more than 90 degrees (relative to the horizontal axis), toward the body of the bag 1010. The roller set 1020 has a lower roller 5ii with a flat surface for supporting the bag 1010, i.e., for the bag to rest on. The lower roller 5ii is not tapered or sloped in the cross-sectional view shown in FIG. 10A.

[0145] Roller set 1022 has an upper roller 6i configured with a steep angle slope to guide the sealed side 1026 folded by roller set 1020 to fold further toward the body of the bag 1010. Roller set 1020 has a lower roller 6ii with a flat surface for supporting the bag 1010, i.e., for resting the bag 1010 thereon. The lower roller 6ii is not tapered or sloped in the cross-sectional view shown in FIG. 10A.

[0146] Roller set 1024 has upper and lower rollers 7i and 7ii, both of which are not tapered or angled in the cross-sectional view shown in FIG. 10A. They are used to fold and hold sealed side 1026 at 180 degrees relative to a horizontal axis. At this angle, the portion of sealed side 1026 that previously had tape / adhesive applied is adhered to the body of bag 1010. Upper and lower rollers 7i and 7ii cooperate to hold and press sealed side 1026 against the body of bag 1010.

[0147] Each roller set in the third roller group is configured similarly to roller set 1024 in the second roller group, as the folding is completed at roller set 1024. The roller sets in the third roller group are provided to apply continuous pressure to the sealed side 1026, thereby strengthening the adhesion of the sealed side 1026 to the body of the bag 1010.

[0148] The distance between the two rows of rollers 1002 and 1004 can be adjusted to accommodate different bag lengths. The distance between the rollers in each row can also be adjusted to accommodate different bag widths. The fixture 1006 or vacuum fixture for holding the bag can be configured accordingly to accommodate different bag dimensions. For example, the length of a bag supported by the apparatus 1000 can be 100 to 550 mm, and the width of a bag supported by the apparatus 1000 can be 70 to 120 mm.

[0149] Table 5 below summarizes the description of the upper and lower rollers of each of roller sets 1012, 1014, 1016, 1018, 1020, 1022 and 1024 and their purpose.

[0150] [Table 7]

[0151] Examples of fully folded or collapsed bags are shown in Figures 25, 25A, 25B, and 25C. These figures will now be described. Note that these figures are not drawn to scale and that the thickness of the folds in the side views shown has been exaggerated for better illustration.

[0152] FIG. 25 shows a back view 25A, a front view 25B, and a side view 25C of a folded bag 2500. The folded bag 2500 has a first folded horizontal seal 2502 (or folded top seal), a second folded horizontal seal 2506 (or folded bottom seal), and a folded vertical seal 2504 (or folded center seal) that is perpendicular to the first folded horizontal seal 2502 and the second folded horizontal seal 2506. The folded vertical seal 2504 is folded when sealed vertically during the bag forming stage in step 218 of FIG. 2, for example, by using the vertical sealer 514 of FIG. 5. Using this folding process, the first folded horizontal seal 2502 and the second folded horizontal seal 2506 are folded. In the example of FIG. 25, all of the folded seals 2502, 2504, and 2506 are visible in the back view 25A. The folded vertical seal 2504 is located at the edge of the folded bag 2500 (at the left edge of the folded bag 2500 with respect to FIG. 25).

[0153] FIG. 25A shows a back view 25D, a front view 25E, and a side view 25F of a folded bag 2510. The folded bag 2510 has a first folded horizontal seal 2512 (or folded top seal), a second folded horizontal seal 2516 (or folded bottom seal), and a folded vertical seal 2514 (or folded center seal) that is perpendicular to the first folded horizontal seal 2512 and the second folded horizontal seal 2516. The folded vertical seal 2514 is folded when sealed vertically during the bag forming stage in step 218 of FIG. 2, for example, by using the vertical sealer 514 of FIG. 5. Using this folding process, the first folded horizontal seal 2512 and the second folded horizontal seal 2516 are folded. In the example of FIG. 25A, all of the folded seals 2512, 2514, and 2516 are visible in the back view 25D. A folded vertical seal 2514 is located in the central region of the folded bag 2500 .

[0154] 25B shows a back view 25G, a front view 25H, and a side view 25I of a folded bag 2520. The folded bag 2520 has a first folded horizontal seal 2522 (or folded top seal), a second folded horizontal seal 2526 (or folded bottom seal), and a folded vertical seal 2524 (or folded center seal) that is perpendicular to the first folded horizontal seal 2522 and the second folded horizontal seal 2526. The folded vertical seal 2524 is folded using the vertical sealer 514 of FIG. 5 when sealing vertically during the bag forming stage in step 218 of FIG. 2. Using this folding process, the first folded horizontal seal 2522 and the second folded horizontal seal 2526 are folded. 25B, fold seal 2524 is visible in rear view 25G, and fold seals 2522 and 2526 are visible in front view 25H. Fold vertical seal 2514 is located in the central region of folded bag 2500.

[0155] FIG. 25C shows a back view 25J, a front view 25K, and a side view 25L of a folded bag 2530. The folded bag 2530 has a first folded horizontal seal 2532 (or folded top seal), a second folded horizontal seal 2536 (or folded bottom seal), and a folded vertical seal 2534 (or folded center seal) that is perpendicular to the first folded horizontal seal 2532 and the second folded horizontal seal 2536. The folded vertical seal 2534 is folded using the vertical sealer 514 of FIG. 5 when sealed vertically during the bag forming stage in step 218 of FIG. 2. Using this folding process, the first folded horizontal seal 2532 and the second folded horizontal seal 2536 are folded. In the example of FIG. 25, all of the folded seals 2532, 2534, and 2536 are visible in the back view 25A. In the example of Figure 25C, fold seal 2534 is visible in back view 25J and fold seals 2532 and 2536 are visible in front view 25K. Fold vertical seal 2534 is located at an edge of folded bag 2530 (at the right edge of folded bag 2530 with respect to Figure 25). In another example, fold vertical seal 2534 can be located at edge 2538 of folded bag 2530 (at the left edge of folded bag 2530 with respect to Figure 25).

[0156] After the folding process, a folding quality control check (corresponding to step 230 in FIG. 2) can be performed. The main purpose of this check is to prevent unfolded or improperly folded bags from entering the subsequent degassing, heating, and cooling processes. Improper folding can lead to bag rupture in downstream processes. The input to the folding quality control check is the folded bags that are discharged from the folding process. The folding quality control check process includes verifying that the sealed sides of each folded bag, i.e., the top and bottom sealed sides, are folded or folded.

[0157] A computer vision system can be used to verify whether both sealed sides of a bag are properly folded or folded. The computer vision system can do this by checking the bag's dimensions, for example, by measuring the bag's length. In this case, if the bag is too long, it indicates that it is not properly folded or folded. FIG. 11 shows an overhead camera 1102 used to capture an image of the bag 1100 to verify whether the length of the bag 1100 meets a predetermined length requirement. This predetermined length requirement is set based on the length of a bag in which both sealed sides are properly folded over. One of the folded sides of the bag 1100 is marked with a check mark, indicating that the folded sealed side is properly adhered to the body of the bag 1100. The other side of the bag 1100 has a sealed side 1104 that appears unfolded and is marked with a cross to indicate that the length of the bag 1100 does not meet the predetermined length requirement.

[0158] Additionally, the computer vision system may be configured to check the height of each bag to identify improperly folded bags. The bag should have a height that includes the thickness of the sealed side. For example, if the bag height is too low, it indicates that the sealed side is not folded or is folded improperly. If the bag height is too high, it indicates that the fold is not fully folded and adhered to the main body of the bag, or that the adhesive is loose and the fold is unfolded. FIG. 11A shows a height sensor 1112, which may be a laser or infrared sensor, for example. The height sensor 1112 is used to check whether the height of the bag 1110 meets a predetermined height requirement, indicated by the dashed line. The predetermined height requirement is set based on the height of a bag in which both sealed sides are properly folded. A check mark is placed on one of the folded sides of the bag 1110, indicating that the folded sealed side is properly adhered to the main body of the bag 1110. The other side of the bag 1110 has a sealed side 1114 that is folded 90 degrees relative to the horizontal axis, causing the measured height to exceed the predetermined height requirement defined by the dashed line. Thus, in Figure 11A, it can be seen that a cross is shown to indicate that the height of the bag 1110 does not meet the predetermined height requirement.

[0159] Bags that pass the turnaround quality check are transferred to the next process. Bags that do not pass the check are rejected.

[0160] After the wrap quality check, the degassing, heating, and cooling process (corresponding to step 232 in FIG. 2) can begin. Degassing, heating, and cooling can be performed sequentially on one bag at a time or on a batch of bags containing multiple bags. Alternatively, the degassing and heating processes can be performed simultaneously on one bag at a time or on a batch of bags, but the cooling process must be separate. The input for the degassing, heating, and cooling process is the folded pouch that has passed the wrap quality control check. If the pre-fold and wrap are skipped, the input will be bags from a previous process that are not skipped.

[0161] The degassing, heating, and cooling process may include an optional first step of leveling the powder inside each bag by vibration, a second step of degassing the bags by mechanical pressing and / or vacuum support (i.e., vacuum suction is applied to degas the bags), a third step of subjecting the bags to a heat treatment, and a fourth step of cooling the bags. The product of the degassing, heating, and cooling process is a heat-treated insulated device. An example heat treatment temperature range may be 130 degrees Celsius to 150 degrees Celsius. The temperature of the insulated device after cooling should drop to below 50 degrees Celsius.

[0162] The types of equipment used in the above processes can be divided into the following categories: 1. Static hot pressing or multilayer hot pressing (MLHP), or 2. Double Belt Press (DBP).

[0163] DBP is more suitable for automated continuous production processes, whereas the MLHP technique is more suitable for static (batch) production processes.

[0164] An example of an MLHP-based device includes a compression and heating chamber for placing one or more bags, where compression and heating of the one or more bags can be performed simultaneously. The same or a separate chamber can be used to cool the one or more bags after compression and heating.

[0165] For example, an optional first step of leveling the powder inside each bag by vibration can be performed outside the chamber using a vibration device that may include a fixture for securing each bag. The fixture can be activated to vibrate to perform powder leveling of the bags. After powder leveling has occurred, the bags are transferred to a compression and heating chamber.

[0166] Alternatively, the chamber may be configured to vibrate to perform powder leveling, in which case there is no need to transfer the bag from the vibration station to the chamber, in which case the vibration process may occur simultaneously with compaction of the bag, where both degassing and powder leveling occur.

[0167] The compression and heating chamber may include multiple plates connected to each other. One or more bags may be placed on every two of the plates. The plates are adjustable to move closer to each other to compress the bags placed between them. A heating element is provided to heat the plates. In this manner, compression and heating can be performed simultaneously. Heating should occur as the bag or bags are compressed. After the heat treatment is performed for a predetermined period of time, the plates, along with the bag or bags compressed between them, are cooled naturally or by active cooling, for example, by directing a cooling liquid through pipes connected to or attached to the plates. Cooling should also occur as the bag or bags are compressed.

[0168] An MLHP-based apparatus may include a control station with one or more processors or controllers that control the process. The control station may have a display that displays a graphical user interface for user control and configuration. The display may be a touchscreen display. The control station may include indicator lights that indicate whether the apparatus is operating, in various stages of operation, or is non-functional. The control station may include multiple user interfaces, such as buttons, knobs, switches, etc., for controlling the apparatus. The apparatus includes one or more motors or engines and a power source for driving its moving parts.

[0169] FIG. 12 shows an example side view of a DBP-based apparatus 1200 that performs the degassing, heating, and cooling processes described above.

[0170] The apparatus 1200 comprises several machine components and zones, which are described below. 1. An infeed zone 1202 for feeding one or more bags from an upstream process; 2. A degassing zone for starting or commencing the process of degassing one or more bags, the degassing zone including a vibration device 1204 for leveling the powder inside the one or more bags; 3. A heating and / or pressure zone 1206 including one or more heating and / or pressure modules, such as modules 1206a, 1206b, and 1206c; 4. A cooling zone 1208 including one or more cooling modules; 5. A discharge zone 1210 for discharging the degassed, heat treated and cooled bags. The product may be referred to as a finished insulation device, after which checks and inspections or further processing may be performed on the finished insulation device.

[0171] In particular, the apparatus 1200 has a modular setup or design that allows heating, compression and / or cooling modules to be plugged in and removed as needed to obtain the best production results.

[0172] FIG. 12A also shows a side view 12A of an apparatus 1200 having a different combination of modules for degassing, heating, and / or cooling compared to FIG. 12. FIG. 12 shows the interior of each module, and FIG. 12B shows the doors covering the interior of each module closed. FIG. 12B also shows a top view 12b of the apparatus 1200 having modules 1-5 (abbreviated: modules 1-5) corresponding to two modules 1206a, one module 1206d, and two modules 1208a shown in side view 12A. The door of module 1 in FIG. 12B is open.

[0173] 12 and 12B, apparatus 1200 includes an upper conveyor 1222 including an upper endless belt 1226 (or first endless belt) and a lower conveyor 1224 including a lower endless belt 1228 (or second endless belt). The belts may be made of interlocking metal pieces such as steel (known as steel belts). Upper conveyor 1222 and lower conveyor 1224 are configured with the necessary motors or engines and drive gears or wheels such as 1236 and 1238 for synchronously driving their respective belts. Lower belt 1228 is used to deliver one or more bags placed thereon in infeed zone 1202 through intermediate zones 1204, 1206, and 1208 and transport them to zone 1210. The one or more bags may be placed by a robot (e.g., a pick-and-place robot) or an interconnected upstream conveyor system.

[0174] The gap between the lower and upper conveyors, on which one or more bags are placed, can be automatically adjusted. The upper belt 1226 contacts the upward-facing surface of each bag transported by the lower conveyor 1224 after the bag has been transported a certain distance by the lower belt 1228. The speed of the conveyor belt movement is adjustable. After the upper belt 1226 contacts the bag and the bag is between the upper and lower belts, the distance between the upper and lower belts 1226 and 1228 gradually decreases. As this distance decreases, the upper and lower belts 1226 and 1228 compress the bag, causing the bag to degas.

[0175] The vibration device 1204 is installed between the infeed zone 1202 and the first heating module 1206a and corresponds to the degassing zone. In this example, the vibration device 1204 includes a vibration member 1230 (which may be a roller or a bar) for contacting the upper belt 1226. The vibrations generated by the vibration device 1204 are guided (through the vibration member 1230) to the upper belt 1226, which further vibrates one or more bags conveyed between the upper belt 1226 and the lower belt 1228. The combination of vibration and compression helps to homogenize the powder inside each bag.

[0176] One or more layers of fabric or coating (e.g., Teflon-based fabric or coating, silicone-coated fabric) can be attached to the surface of the upper belt 1226 and the lower belt 1228 that contacts the bag(s). These one or more layers of fabric or coating help ensure that air can flow from the inside of the bag through the perforations in the bag. The one or more layers of fabric or coating can be configured with a pattern that, under pressure, imprints such a pattern on the surface of the bag that contacts the one or more layers of fabric or coating. Such an imprinted pattern can help improve the rigidity of the bag.

[0177] As previously mentioned, the apparatus 1200 has a modular configuration for compression, heating, and / or cooling. Such heating, pressure, and / or cooling modules can be arranged according to the required process. Each module includes an upper or top plate 1232 and a lower or bottom plate 1234, which are adjustable toward or away from each other to apply or release pressure to an object placed between the upper plate 1232 and the bottom plate 1234. In the apparatus 1200, the upper plate 1232 and the bottom plate 1234 do not directly contact the bag or bags. When pressure is applied to a bag between the upper belt 1226 and the lower belt 1228, the upper plate 1232 presses against the upper belt 1226, and the bottom plate 1234 presses against the lower belt 1228.

[0178] The temperature of each module can be controlled individually. The compression provided by the modules can exert pressure on one or more bags in addition to the pressure exerted through adjustment of the distance between the upper belt 1226 and the lower belt 1228. The pressure exerted by the modules on the upper belt 1226 and the lower belt 1228 can be adjusted within a predetermined range. The pressure, heating and / or cooling conditions can be different for each individual module within the heating and / or pressure zone 1206 and the cooling zone 1208.

[0179] Examples of modules in a modular setup are 1206a, 1206b, 1206c, and 1208 in Figure 12, 1206d, 1206b, 1206c, 1212, and 1214 in Figure 12A, and 1206a, 1206d, and 1208a (and corresponding modules 1-5) in Figure 12B. Table 6 below lists the abbreviations used for the modules in Figures 12, 12A, and 12B and their corresponding descriptions. See pressure versus time graphs G1-G5 for modules 1206d, 1206b, 1206c, 1212, and 1214, respectively, shown in Figure 12A.

[0180] [Table 8]

[0181] In Table 6, "sliding plates" means that the module comprises two plates that can slide vertically toward or away from each other. Note that the pressure application profile for each module can be adjusted as needed to achieve best results and is not limited to the profile shown in the graph in Figure 12A.

[0182] The module combination of two heating modules (SPM-H) 1206a (or modules 1 and 2), one high-pressure module (SPM-H-HP) 1206b (or module 3), and two cooling modules (SPM-C) 1208a (or modules 4 and 5), shown in side view 12A of Figure 12B, is recommended for making an insulating device according to an example of the present disclosure, although it should be understood that other possible module combinations are also possible.

[0183] For illustrative purposes, the following describes the heat treatment and cooling process of one or more input bags based on the module combination shown in Figure 12B. The operating temperature range can be 20 to 250 degrees Celsius, with temperatures near the upper limit being used for heat treatment and temperatures near the lower limit being used for cooling. An example belt width of the upper belt 1226 and the lower belt 1228 can be 1 to 1.5 m. The belt movement speed (or line speed) can be 0.1 to 4 m / min.

[0184] A control station 1216, which may include one or more processors / controllers and may include one or more displays (i.e., monitors (e.g., based on LCD, LED, OLED, etc.), touch screens, etc.) for displaying a graphical user interface for user control and / or one or more user input / output interfaces (buttons, mouse, keyboard, etc.), may be electrically connected to the apparatus 1200 and modules to provide control over moving parts (e.g., adjusting positioning, adjusting orientation, switching on / off, etc.), sensors, and process parameters (e.g., line speed, pressure, temperature, etc.). Wiring / cables and other necessary electrical components / equipment may be stored in provided electrical cabinets 1220a and 1220b. The apparatus 1200 also includes a power supply.

[0185] After powder leveling, heat treatment of one or more bags is performed in modules 1-3. The temperature is gradually increased in modules 1 and 2, meaning that the temperature in module 2 is higher than that in module 1. This increase in temperature assists the ongoing degassing process as the air expands inside each bag due to the increased temperature. A low pressure may or may not be applied by the plates of modules 1 and 2 individually. However, a preset compression of the upper belt 1226 against the lower belt 1228 may still be performed, and one or more bags will still be subjected to this compression.

[0186] Module 3 is where the final (or highest) heating temperature is reached. Additionally, Module 3 applies high pressure to the bag(s). The higher pressure ensures that the bag(s) are properly compressed. The pressure profile of Module 3 can follow graph G2 in Figure 12A, or other pressure profiles as needed.

[0187] Modules 4 and 5 are used for the cooling process. Active cooling is performed by modules 4 and 5, where the plates of modules 4 and 5 are cooled or cooled to a low temperature by on-site chillers or coolers 1218a and 1218b (e.g., 30 kW rated). Modules 4 and 5 are configured so that one or more bags are kept under compression during the cooling process. A constant pressure can be applied. The cooling process can gradually reduce the temperature of each bag to the required level of less than 50 degrees Celsius, meaning that the temperature of module 5 is lower than that of module 4. After the requirement is met, the cooling process is considered complete, and one or more bags are transferred to the output zone 1210 of the apparatus 1200, which transfers the produced product, i.e., the insulation device, to the next process.

[0188] Another type of double-belt press apparatus may be used for the degassing, heating, and cooling process. The primary difference between such an apparatus and the described apparatus 1200 may be the belt material of the upper belt 1226 and the lower belt 1228. Instead of a steel belt, a three-layer (non-steel) construction belt may be used. With such a belt, the overall pressure that may be applied during the process will be lower than with a steel belt. In other examples, apparatuses that use a vacuum to apply pressure and / or rollers to apply pressure and provide heating may be used as well.

[0189] After the degassing, heating, and cooling processes, the fabricated insulating devices can be subjected to a second cleaning process (corresponding to step 234 in FIG. 2). The purpose of the second cleaning process is to clean the insulating devices in case they become contaminated with powder from a leaking bag or a ruptured bag. The input to the second cleaning process is the fabricated insulating devices. The second cleaning process is the same as the first cleaning process described above. A cleanliness check similar to that described above can be performed to check the cleanliness of each cleaned insulating device. Cleaner insulating devices are transferred to the next process, while less clean insulating devices are rejected.

[0190] As with the first cleaning process, the same cleaning device (i.e., the same cleaning device as for the first cleaning process) or a second cleaning device equipped with air nozzles and / or brushes can be used. The device can include a control station with one or more processors or controllers for controlling the process. The control station can have a display displaying a graphical user interface for user control and configuration. The display can be a touchscreen display. The control station can include indicator lights that indicate whether the device is operating, in various stages of operation, or non-functional. The control station can include multiple user interfaces, such as buttons, knobs, switches, etc., for controlling the device. The device includes one or more motors or engines and a power source for driving its moving parts.

[0191] After the insulation device has been cleaned, an optional, but recommended, end-of-life (EOL) inspection process (corresponding to step 236 in FIG. 2) can be performed. The input to this EOL inspection process is the cleaned insulation device. The inspection performed may include one or more of the following: a) Check the weight of the insulation device inserted to ensure that it meets a predetermined weight requirement (for example, the concept of apparatus 600 in FIG. 6 may be adopted). b) Checking the dimensions of the insulating device to ensure that it meets predetermined dimensional (e.g., width, length, thickness, and / or height) requirements (e.g., computer vision techniques similar to those described with reference to Figures 11 and 11A can be used). c) Check the visual appearance of the insulating device for wrinkles and check the flatness of the insulating device (e.g., computer vision techniques similar to those described with reference to Figures 11 and 11A can be used). d) Inspect the insulation device to ensure there are no powder leaks (e.g., computer vision techniques similar to those used for cleanliness checks can be used).

[0192] Insulation devices that pass all inspection tests can be transferred to the next process, which is to label or mark the insulation device. Defective devices are rejected.

[0193] FIG. 13 shows an example of an apparatus 1300 for performing the EOL inspection process and labeling of insulation devices. The apparatus 1300 includes a weight test station 1304 equipped with one or more load cells to weigh each insulation device introduced, a visual / dimensional check station 1306 for performing surface appearance and dimensional checks on each insulation device introduced, a powder leak check station 1308 for checking each insulation device for powder leaks, a rigidity check station 1310 for checking the rigidity of each insulation device introduced, and a labeling station 1312 for applying desired labels and / or markings to each good insulation device. The output of the apparatus 1300 is a good insulation device bearing the label and / or marking. The apparatus 1300 includes multiple transfer units 1302, which may be robotic arms used to pick up and place insulation devices to transport the insulation devices between stations.

[0194] The apparatus 1300 may include a control station (not shown) with one or more processors or controllers that control the process. The control station may have a display that displays a graphical user interface for user control and configuration. The display may be a touchscreen display. The control station may include indicator lights that indicate whether the apparatus 1300 is operating, in various stages of operation, or is non-functional. Multiple user interfaces, such as buttons, knobs, switches, etc., may be provided on the control station for controlling the apparatus 1300. The apparatus 1300 includes one or more motors or engines and a power source for driving its moving parts.

[0195] Specifically, at weight test station 1304, the inserted insulation device is weighed to check whether its weight meets the tolerance requirements. Preferably, a weight deviation of 5% or less should be met compared to a predetermined desired weight value. Insulation devices that pass the weight test are transferred by transfer unit 1302 to appearance check station 1306. Insulation devices that fail are transferred to a reject bin.

[0196] At the appearance / dimension check station 1306, the introduced insulation devices are measured to determine whether their dimensions meet the tolerance requirements. A computer vision system is used to check the length and width of the insulation devices. The tolerance requirements to be met can be a deviation of ±1 mm from a predetermined desired width value and a predetermined desired length value. Another part of the appearance / dimension check is a thickness check. The thickness can be checked by a computer vision system and / or a mechanical measuring device such as a thickness gauge. Other suitable methods other than computer vision can also be used to physically measure the length, width, and / or thickness and determine whether they are within the tolerance requirements. Insulation devices that pass the dimensional test are transported by the transfer unit 1302 for a visual appearance check. Insulation devices that fail the dimensional test are transferred to a reject bin. An appearance check is performed to ensure that the introduced insulation devices meet the appearance requirements. The surface of the insulation device should be free of wrinkles. The flatness of the insulation device is checked to ensure that there is no significant distortion or warping of the insulation device. The visual appearance may be checked using a computer vision system configured for 2D and / or 3D imaging, a laser sensor, and / or an X-ray system. Insulation devices that pass the visual test are transported by the transport unit 1302 to a powder leak check station 1308. Insulation devices that fail are placed in a reject bin.

[0197] At powder leak check station 1308, the loaded insulation devices are checked to ensure there are no powder leaks. The powder leak check may be performed using a computer vision system. Powder detected in the captured image of the insulation device is an indication of a leak. If the insulation device had a large powder leak, it would have failed the upstream weight test station 1304. Insulation devices that pass the powder leak test are transported by transfer unit 1302 to rigidity check station 1310. Insulation devices that fail are placed in a reject bin.

[0198] At the rigidity check station 1310, the introduced insulation device is checked to ensure that the required rigidity is met. For example, the insulation device may be gripped at two ends and a predetermined tension or pressure applied to determine whether the insulation device bends, distorts, or warps. If no bending, distortion, or warping is detected when the tension or pressure is applied or after the tension or pressure is released, the insulation device passes the rigidity test, for example, by a computer vision system. Another method may be to apply a predetermined force to the insulation device via a pin or measuring plate. The distance the pin or plate moves after applying the force is measured. If the distance exceeds a predetermined value, the insulation device is not deemed sufficiently rigid and is rejected. Insulation devices that pass the rigidity test are transferred by the transfer unit 1302 to the labeling station 1312. Insulation devices that fail are placed in a reject bin.

[0199] At labeling station 1312, the inserted insulation devices are labeled. An inkjet printer or laser marking system can be used. The labeling can include product information (e.g., model number, batch number, etc.) and / or manufacturing date.

[0200] After labeling is complete, an optional taping process (corresponding to step 238 in FIG. 2) can be performed on the labeled insulating device. The need for such taping depends on the application requirements. For example, such taping may be required to facilitate securing the insulating device to the battery cell during battery assembly. The tape / adhesive may be an adhesive tape with an extended release liner. Such an extended liner may help simplify the battery assembly process.

[0201] The inputs to the taping process are adhesive and liner or liner-attached transfer tape, and labeled insulation devices or insulation devices that have passed the EOL inspection check if labeling is skipped. The taping process involves applying adhesive to the body, particularly to the major (front and back) surfaces of each insulation device, and providing a release liner over the adhesive. The adhesive can be in liquid form and sprayed onto the major surfaces of the insulation device. Alternatively, a double-sided or transfer tape with a release liner on one side can be adhered to the major (front and back) surfaces of each insulation device. The output of the taping process is an insulation device with tape / adhesive and a release liner on one or both major surfaces.

[0202] Specifically, the taping process can begin by aligning the insulating device using a tape or adhesive applicator. 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 over the applied adhesive. In another example, a single-sided tape with a release liner on one side can 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 with two sides having release liners, the release liner or one side of such tape is first removed to apply the tape to the desired surface of the insulating device. The tape can be cut to the appropriate size before or after (preferably before) the tape is adhered to the desired surface of the insulating device.

[0203] The tape or adhesive applicator may be part of the apparatus (not shown). Such an apparatus may include a control station with one or more processors or controllers that control the process. The control station may have a display that displays a graphical user interface for user control and configuration. The display may be a touchscreen display. The control station may include indicator lights that indicate whether the apparatus 1300 is operating, in various stages of operation, or is non-functional. Multiple user interfaces, such as buttons, knobs, switches, etc., may be provided on the control station to control the apparatus. The apparatus may further include one or more motors or engines and a power source for driving its moving parts.

[0204] If the two major surfaces of the insulating device are taped or coated with adhesive and a release liner, the taping process described above is first performed on one major surface of the insulating device. The insulating device is then rotated and aligned with the tape or adhesive applicator. In the case of double-sided tape, the required tape length can be cut before applying the tape to the desired surface of the insulating device on the other major surface. If adhesive application is involved, the adhesive is prepared and applied to the desired surface of the insulating device on the other major surface. In the case of double-sided tape or transfer tape, two applicators can be used to apply the tape to both sides of the insulating device simultaneously or sequentially. For example, a first applicator is positioned above the first major surface of the insulating device, and a second applicator is positioned below the second major surface of the insulating device. The insulating device is held suspended at a distance from the second applicator, with the second major surface being the surface opposite the first major surface.

[0205] As an additional feature, if desired, the release liner of the insulating device may be subjected to a labeling process to label or mark the release liner with desired markings / labels.

[0206] FIG. 14A illustrates different scenarios 1408, 1410, 1412, and 1413 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 1408, tape or adhesive 1408a is applied to the entire major surface of the insulating device. For scenario 1410, tape or adhesive 1410a is applied over a predetermined surface area of ​​the insulating device. For scenario 1412, tape or adhesive 1412a is applied over a surface area that varies relative to the width of the insulating device. That is, the surface area over 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 1414, tape or adhesive 1414a is applied over a surface area that varies relative to 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 may be located the same distance from the length boundary end of the insulating device. The length boundary end refers to the ends located opposite each other and separated by the distance of the length of the insulating device. Furthermore, two or more other tapes or adhesives 1414b covering a given surface area may be applied in a given location. In this scenario, the tapes or adhesives 1414b are relatively small in size compared to the tapes or adhesives 1414a. Removable release liners should be provided for the applied tapes or adhesives 1408a, 1410a, 1412a, 1414a, and 1414b to enable them to be attached to surfaces as needed.

[0207] After or during the taping process, the insulating device may be subjected to a taping quality check process (corresponding to step 240 in FIG. 2 ). This taping quality check process may check that the tape or adhesive is properly applied to the insulating device. The taping quality check process may check for correct positioning of the tape / adhesive on one or both major surfaces of the insulating device based on a predetermined determination of where the tape / adhesive will be applied. The visual appearance of the tape / adhesive may be checked, for example, a visual check to ensure that the release liner is properly applied. If a visual check is performed during the taping process, the applied adhesive may be checked to ensure that there are no air bubbles. After the taping process is complete, proper tape or adhesive application and adhesive bubbles may also be checked. This may be done by a computer vision system. Air bubbles are visible even when the release liner is attached to the tape or adhesive. A peel adhesion test of the adhesive may also be performed, but this may be an offline random check that is not performed on every bag. Insulating devices that pass the taping quality check are transferred to the next process. Insulating devices that do not pass are moved to a reject bin.

[0208] A computer vision system with a camera or imaging sensor can be used to check the position of tape or adhesive on an insulating device. FIG. 14 shows an example of a camera 1402 of such a computer vision system being used to check tape with a release liner 1404 applied to an insulating device 1406. For example, a requirement can be set that the desired position or location of the tape or adhesive application must not deviate by more than ±1 mm from the predetermined position or location on the insulating device where the tape or adhesive is applied. A computer vision system can also be used to check for air bubbles and proper tape or adhesive application. The peel adhesion strength requirement for the applied adhesive to pass the peel adhesion test can be 8 N / 25 mm or greater.

[0209] After the taping quality check, or if the taping process is skipped, after the insulating devices pass the EOL inspection, they are ready to be packaged via a packaging process (corresponding to steps 242-246 in FIG. 2). This packaging process can be fully automated. The insulating devices can be packaged in cardboard or reusable containers (or boxes). Before the insulating devices are packaged in the container, a stacking process should be performed in which the insulating devices are stacked. Such stacking groups, compresses, and bundles multiple insulating devices together, thereby maximizing the storage space of the container. The insulating devices are oriented, positioned, and tied in a predetermined manner to prevent any adverse effects on the product (i.e., insulating device) properties during shipping (e.g., colliding with other insulating products, resulting in powder leakage or bag rupture).

[0210] 15 and 15A, the stacking process can include stacking multiple thermal insulation devices one at a time between two plates. The two plates can be made of cardboard, plywood, reusable plastic boards, foam (e.g., expanded polystyrene), etc. Initially, a bottom plate 1504 is positioned to form a base for stacking multiple thermal insulation devices. Specifically, FIG. 15 shows four stacked thermal insulation devices 1502 stacked on top of the bottom plate 1504. A single thermal insulation device 1500 is about to be stacked on top of the four stacked thermal insulation devices 1502. As the single thermal insulation device 1502 is stacked on top of the stack of thermal insulation devices 1502, pressure can be applied to the stacked thermal insulation devices 1500. After a predetermined number of thermal insulation devices have been stacked, the stacking of the thermal insulation devices is complete, and a top plate 1506 is stacked on top of the complete stack of thermal insulation devices 1510. Once the top plate 1506 is stacked, pressure can be applied to the stacked thermal insulation devices 1510. After the top plate 1506 is stacked on the top insulation device, the stack of insulation devices 1510 between the top plate 1506 and bottom plate 1504 is tied down using string 1508. The product of the stacking process is a tied-down bundle of insulation devices 1510.

[0211] The stack of insulating devices is preferably stacked under a predetermined pressure. Tie-down may also be performed to maintain a predetermined compression between the stacked insulating devices. This helps maintain the required thickness of the insulating devices and prevents them from expanding (which may occur over time due to their micro-perforations).

[0212] After the insulating devices are stacked into bundles, the bundles can be packed into final packaging, such as cardboard or reusable containers. Since expansion of the insulating devices should be prevented, in one example, vacuum packaging or packing can be performed. Vacuum packing is a packaging method in which air is removed from the package before sealing. This method includes placing the item in a plastic film package, removing air from the inside, and sealing the package.

[0213] To carry out the stacking and / or packaging process described above, a stacking and / or packaging apparatus may be provided that includes a pick-and-place robot, a strapping machine, and the like. The apparatus may include a control station that includes one or more processors or controllers that control the process. The control station may have a display that displays a graphical user interface for user control and configuration. The display may be a touchscreen display. The control station may include indicator lights that indicate whether the apparatus is operating, in various stages of operation, or is non-functional. Multiple user interfaces, such as buttons, knobs, switches, and the like, may be provided on the control station for controlling the apparatus. The apparatus includes one or more motors or engines and a power source for driving its moving parts.

[0214] Multiple framed insulation devices described below can be stacked, bundled, and packaged in the same manner as described above.

[0215] (D) Framed insulation device In this disclosure, a framed insulating device is (1) An insulating device as described with reference to the preceding figures, having framed sides and / or edges; or (2) A combination of a thermal insulation device and / or another thermal insulation device layered with one or more sheets of a flame-retardant device, such as the aforementioned flame-retardant (FR) device, having framed sides and / or edges. The framed insulation device may also be fitted with other examples of flame retardant devices of the present disclosure.

[0216] In the examples of this disclosure, the described insulation devices, FR devices, thermally expandable sheets and framed insulation devices are generally flat, thin and have two major surfaces.

[0217] The frame structure used to frame the insulation device or its combination with other materials can be used to frame all sides and / or edges of the insulation device or its combination, or to frame only one or more selected sides and / or edges of the insulation device or its combination. The frame structure can be made of silicone or other suitable material.

[0218] When the framed insulation device is used in a battery, such as an electric vehicle battery, the frame structure can serve to improve the mechanical performance of the insulation device to which the frame is attached. The framed insulation device can suppress the expansion pressure of the battery cell over the life of the cell, even in high-temperature environments. The frame structure ensures that the thickness of the insulation device (e.g., the insulation device or a combination thereof) is maintained throughout the entire life of the battery cell (i.e., from the beginning of life to the end of life). The thickness of the frame structure can be substantially (or close to) the thickness of the insulation device or its combination with other products or devices. When the material of the frame structure is silicone, it can be flexible and expandable.

[0219] 16 shows four products (or compositions or devices) 1600, 1610, 1620, and 1630 that can be used with or without the frame structure described above. A thermally intumescent (flame-retardant) sheet 1612, which may or may not be the flame-retardant device 1602 described above, can be adhered or placed on one or more major surfaces of the thermal insulation device 1608. In place of the thermally intumescent sheet 1612, a thermally intumescent coating (also given reference number 1612 in FIG. 16) can be coated on one or more major surfaces of the thermal insulation device 1608. Examples of such thermally intumescent coatings include flame-retardant paints and impregnation liquids that can be used to make the flame-retardant device 1602.

[0220] Product 1610 comprises an insulating device 1608 and two thermally expandable sheets or coatings 1612 disposed on two major surfaces of insulating device 1608 .

[0221] Product 1600 comprises an insulation device 1608 and two flame retardant devices 1602 disposed on two major surfaces of insulation device 1608. An adhesive in the form of a coated film, such as tape or adhesive film 1614, can be used to adhere the two flame retardant devices 1602 to insulation device 1608.

[0222] Product 1620 includes two thermal insulation devices 1608 disposed on two major surfaces of one layer of thermally intumescent sheet 1612, which may be the aforementioned flame retardant device 1602. Thermally intumescent sheet 1612 of product 1620 may also be the aforementioned thermally intumescent coating (also given reference number 1612 in FIG. 16).

[0223] Product 1630 includes one thermal insulation device 1608, which may be the flame retardant device 1602 described above, disposed on one major surface of one layer of thermally expandable sheet 1612.

[0224] The following disclosure presents an example process for manufacturing a framed insulation device and some of the equipment used. The components and assembly of the example framed insulation device are also described.

[0225] FIG. 16A shows a top view 16A and a cross-sectional view 16B of a first example of a framed insulation device 1600a. The framed insulation device 1600a includes an insulation device 1608 and two layers of a flame-retardant (FR) device 1602. Each layer of the FR device 1602 is disposed on either side of a major surface of the insulation device. The insulation device 1608 is sandwiched between the two layers of the FR device 1602. A frame structure 1604, comprised of upper and lower frame layers, is provided to cover the sides or edges along the periphery of the insulation device 1608. A seal 1606 is provided on each major surface of the framed insulation device 1600a. The seal 1606 forms an outer protective layer over the exposed major surfaces of the two layers of the FR device 1602.

[0226] Figure 16B shows a top view 16C and a cross-sectional view 16D of a second example of a framed insulation device 1600b. Common elements between Figures 16A and 16B are given the same reference numerals. The framed insulation device 1600b includes an insulation device 1608, the sides or edges of which along the periphery are sandwiched within a frame structure 1604 comprised of upper and lower layers of a frame. A layer of sealant 1606 is provided on each major surface of the framed insulation device 1600b. The sealant 1606 forms an outer protective layer over the exposed major surfaces of the insulation device 1608.

[0227] Examples of size and weight ranges for framed insulation devices and their combinations with and / or without frames and with and without flame retardant devices for electric vehicle battery applications are shown in Table 7 below.

[0228] [Table 9]

[0229] FIG. 16C shows a top view 16C of FIG. 16B, a cross-sectional view 16D of FIG. 16B, and an enlarged view of cross-sectional view 16B of FIG. 16A. FIG. 16C shows specific examples of possible dimensions for a first example of a framed insulation device 1600a and a second example of a framed insulation device 1600b. The length and width of the framed insulation device 1600b may be approximately 148 mm and 98 mm, respectively. The framed insulation device 1600a (top view 16a not shown in FIG. 16C) may similarly have the same length and width. The thickness of the framed insulation device 1600a and the framed insulation device 1600b may be approximately 3 mm, excluding the seal portion 1606. Each of the two layers of the frame structure 1604 in the framed insulation device 1600a and the framed insulation device 1600b may be approximately 1.5 mm thick. The insulation device 1608 in the framed insulation device 1600b may have a thickness of 2 mm. Each of the two layers of the flame retardant device 1602 in the framed insulation device 1600a may be approximately 0.5 mm thick. The insulation device 1608 in the framed insulation device 1600a may have a thickness of 2 mm.

[0230] (E) Manufacturing process of the framed insulation device An example of a method for manufacturing a framed insulating device and combinations thereof is shown in Figure 17 and described below. The manufacturing method includes a bag preparation and filling step 1702, a framing step 1704, an evacuation step 1706, an FR device insertion step 1708, and a sealing step 1710. The framed insulating device comprises an insulating device in the form of a bag containing insulating particles as described above.

[0231] Step 1702 of preparing and filling a bag may include steps 202-230 of FIG. 2 (with or without the steps previously mentioned as optional). Examples of steps 202-230 described with reference to FIGS. 3-11A may include those described above. Step 230 precedes step 232 of degassing, heating, and cooling. The product of step 1702 may be a bag of insulated device that has not yet been degassed, heat-treated, and cooled. Further examples of step 1702 are described below. Alternatively, the product of step (A) may be a bag made by the method of FIG. 2 (with or without the optional steps) (i.e., a bag that has already been degassed, heat-treated, and cooled).

[0232] A framing step 1704 receives the product of step 1702. More details regarding the framing step 1704 are provided below. The product of step 1704 is a framed insulation device. A degassing step 1706 is similar to the degassing portion of step 232 of Figure 2, except that the input to step 1706 is a framed insulation device. Further examples of step 1706 are provided below.

[0233] After or before degassing, a step 1708 of inserting FR devices can be performed to insert one or more FR devices into the framed insulating device.

[0234] Step 1710 preferably includes sealing the framed insulation device immediately after the FR device is inserted into the framed insulation device.

[0235] FIG. 18 shows an example of a film material 1800 that can be used to fabricate a bag for a thermal insulation device. The composition of the film material 1800 includes a polyethylene terephthalate (PET) layer, a glass fiber (EG) layer (e.g., a woven or nonwoven E-glass textile, fabric, or mat), and a polyethylene (PE) layer (film material abbreviation: PET / EG / PE). The PET layer is the outermost layer (corresponding to FML1 in FIG. 1), the EG layer is an intermediate layer (corresponding to FML2 in FIG. 1) between the outermost and innermost layers, and the PE layer is the innermost layer (corresponding to FML3 in FIG. 1). In this example, the PE layer contacts the insulating particles packed into the bag (the optional FF4 in FIG. 1 is absent). The film material 1800 is formed by thermal lamination of three layers of material. The film material 1800 is similar to the example in FIG. 1, and no adhesive is used. During lamination, the PET and PE polymer layers, along with the EG layer, soften or melt and bond to one another. The boundaries between the three layers may not be as clearly defined (i.e., the materials may be intermixed) as the boundaries between the two layers of material shown in the example of Figure 1C. The thickness of the film material 1800 is the thickness of all three layers combined, which may be approximately 120 μm.

[0236] The surface of the film material 1800 is perforated. Such perforations are provided for ventilation purposes and to facilitate degassing of the resulting bag. The size of each perforation must be smaller than the size of the insulating particles to be filled into the bag. For example, as previously mentioned, the average diameter of the perforations may be 15 μm or less. To provide sufficient passage for air / pressure release, the center-to-center spacing of the perforations may be approximately 3×3 mm. FIG. 18A shows a close-up of a sample of the film material 1800 containing perforations 1802. FIG. 18B shows a sample of an actual bag 1804 that can be fabricated. This bag 1804 in FIG. 18B has four-sided seals instead of the three-sided seals of the previously described bag.

[0237] Instead of EG, aluminum (AL) can be used as the middle layer of the film material. The abbreviation for such a film material is PET / AL / PE. The properties of the EG woven mat and AL are shown in Table 8 below.

[0238] [Table 10]

[0239] The tensile strength and thermal conductivity of two example film materials are shown in Table 9 below.

[0240] [Table 11]

[0241] 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 10 below.

[0242] [Table 12]

[0243] An example will now be described for step 1702 of FIG. 17 regarding bag preparation and filling for a four-side sealed bag (e.g., 1804 in FIG. 18B). The bag preparation and filling process performed in step 1702 may include three main steps: bag forming, bag filling, and bag sealing. These three steps may be performed using equipment (or machinery or machine) customized for the process. The equipment may be an Effytec machine called a GP26. Table 11 below shows an example of customized (unique) GP26 machine specifications for the bag preparation and filling process to create a four-side sealed bag.

[0244] [Table 13]

[0245] FIG. 19 shows the essential components of a customized GP26 machine 1910.

[0246] Referring to Figure 19, cover (or film) material for the bag in the form of film or tape is supplied from two bulk rolls mounted on a reel shaft 1 and a second reel shaft 2, respectively. Splicers 3 and 4 are used to join the two pieces of cover material supplied from the two shafts 1 and 2, respectively. The cover material joined by the splicers is then perforated by a perforation punch 5. An unwind retraction roller 6 and a retraction tensioner 7 are used to straighten the joined cover material.

[0247] In another example, only a single bulk roll of film of cover material attached to one reel shaft 1 or 2 may be used. The other respective reel shaft 2 or 1 may be absent or may still be present to provide a supply of film of cover material when the currently used reel shaft runs out of film. When only a single bulk roll of film of cover material is used, the single bulk roll of film may feed two adjacently positioned pieces of film (i.e., already spliced ​​at their major surfaces) directly from the single bulk roll of film of cover material. In this case, the splicers (e.g., 3 and 4) are used to straighten and / or guide the film, not to splice the film. This example differs from the concept of feeding two separate pieces of film from two bulk rolls and splicing them together using splicers 3 and 4, as described in the previous example.

[0248] In a further example, two film pieces of cover material to be joined may be provided from one single bulk roll rather than being supplied from two different bulk rolls, in which case a cut may be required to provide two streams of film of cover material for joining by a splicer, such as splicers 3 and 4.

[0249] In yet another example, only one bulk roll of film of cover material can be used, correspondingly using one reel shaft. The bulk roll of film can be already sealed on one or more sides. For example, the film can be folded to form a sealed side and two major surfaces of the bag. In this case, fewer sealing jaws are required. For example, the bottom surface can be already sealed (or formed by folding the film) so that the top surface can remain open for filling, and only top, left, and right sealing jaws are required. In another case, even if the supplied film is folded to form a sealed side, this sealed side can still be sealed by a sealing jaw (e.g., bottom sealing jaw 10) to further secure it.

[0250] The presence and use of perforation punch 5 is optional, and bag perforation may be optional. In another example, the perforations made by punch 5 may be skipped. In this case, the film or films of cover material are already perforated when they are provided from one or more bulk rolls, or no perforations are provided in the bag.

[0251] A forming plow 8, configured for automatic film registration, is used to rotate and align one or more films of supplied cover material, allowing three sealing jaws 10, 11, and 12 to seal and form the three sides of the bag: the bottom, left, and right sides, respectively. Heat sealing is used. The resulting bag is angular or rectangular in shape, so that once the three sides are sealed, the top side remains open for filling the bag with material. After sealing the three sides, the bag moves to a cooling jaw 13 to cool the seals formed on the three sides. The bag then moves to the cutting die unit area, where the sealed left and right sides of the bag are cut. A pair of scissors 17 with a scissors gripper 18 is used to grip the bag at one end (e.g., grip the sealed right side of the bag). After the scissors gripper 18 grasps the bag and sets it in place for cutting, a servo film tensioning unit 15 is used to stretch / clamp the opposite end of the bag (e.g., stretch / clamp from the sealed left side of the bag). After cutting, the cut bag moves to an opening station where the top side of the unopened bag is opened.

[0252] A lower vacuum cup 20 is used to hold the sealed bottom of the bag, and a blow cone 21 is used to open the unsealed top of the bag. Upon detecting the opening, the opened bag moves to one or more filling stations, such as a first filling station 22, a second filling station 23, and more as needed, for filling with the required material. Each filling station may use a cone to fill the bag. The bag may be filled with insulating particles in powder form. After filling, the filled bag moves to a stretching station 24 to stretch the open side of the bag closed. The top of the bag may then be sealed using one or more upper sealing jaws, such as a first upper sealing jaw 25 and a second upper sealing jaw 26. Heat sealing and / or ultrasonic sealing processes may be considered for sealing. The top of the bag is then cooled using an upper cooling jaw 27. After cooling, the bag is formed and exits the GP26 machine 1910 system. The bag may exit to a "reject" station for quality checks; for example, the bag may be rejected if it is weighed incorrectly.

[0253] The photocell is a light-sensitive module, which may be a resistor that changes resistance depending on the amount of light incident on the photocell. A number of such photocells (e.g., 4, 9, and 16 in FIG. 19) are used as sensors for precise positioning and / or alignment during the bag forming process.

[0254] A computer / control system comprising one or more processors / controllers and which may comprise one or more displays (i.e., monitors (e.g., based on LCD, LED, OLED, etc.), touch screens, etc.) displaying a graphical user interface for user control and / or one or more user input / output interfaces (buttons, mouse, keyboard, etc.) may be connected to the GP26 machine to provide control over moving parts (e.g., adjusting positioning, adjusting orientation, switching on / off, etc.), sensors (e.g., photocells), and process parameters (e.g., line speed, pressure, temperature, etc.) within the GP26 machine 1910. The GP26 machine 1910 also comprises one or more motors or engines and a power source for driving its moving parts.

[0255] The bags produced by the GP26 machine 1910 described above are four-sided sealed bags. FIG. 19A shows an example of a four-sided sealed bag 1900 produced by the GP26 machine 1910. A sealed region 1904 extends from the body of the bag 1902 to the periphery of the bag 1900. The body of the bag 1902 contains insulating particles, i.e., powder, packed within the bag 1900. The width of the sealed region 1904 around the periphery of the bag 1900 can be approximately 6 mm. The GP26 machine 1910 (for four-sided sealed bags) and other equipment (for three-sided sealed bags, e.g., apparatus 400 of FIG. 4) can be customized or modified to accommodate various requirements.

[0256] An example will now be described for step 1704 of FIG. 17 regarding framing for a three or four side sealed bag of insulation device.

[0257] The framed insulation device and its variations may be constructed from two frames. In the example described below, the bag that constitutes the insulation device is sandwiched between a lower frame layer (or lower frame) and an upper frame layer (or upper frame). The frame layers cover the sides, edges, or borders around the periphery of the insulation device or its combination with other material layers. In another example, two or more insulation devices may be sandwiched.

[0258] In this example, the insulation device is sealed on all four sides and rectangular in shape. Correspondingly, each of the upper and lower frame layers (or lower frames) is four-sided, rectangular in shape, and configured to cover each side boundary of the insulation device. In another example, the insulation device and frame may be angular, circular, or any other shape, and the frame structure (composed of the upper and lower frame layers) is configured to cover the perimeter of such a shape. Table 12 below shows an example of frame specifications.

[0259] [Table 14]

[0260] FIG. 20 illustrates three process steps for framing an insulation device 2004, which is an example of the insulation device 2004 described above. A framing machine (not shown) can be used. Such a framing machine can include a frame feeder that supplies an upper frame 2006 and a lower frame 2002. The frame feeder can be a magazine or a stack. A pick-and-place robot, for example, a six-axis robot, can be used during frame assembly. Such a robot is included in the framing machine. In the first step (1.), the lower frame 2002 is placed on a platform or fixture of the framing machine. In the second step (2.), one or more bags of insulation device 2004 are placed on the lower frame 2002. In the third step (3.), the upper frame 2006 is placed on the insulation device 2004. After the third step, the insulation device 2004 is sandwiched between the upper frame 2006 and the lower frame 2002. For the insulation device 2004 bonded to the upper frame 2006 and the lower frame 2002, there are intermediate bonding steps between the first step (1.), the second step (2.) and the third step (3.).

[0261] FIG. 20A shows how the bag of insulation device 2004 can be bonded to the lower frame 2002 and upper frame 2006 of FIG. 20 via adhesive 2010. FIG. 20A shows a top view of one of the frames 2002 or 2006 and a top view of insulation device 2004. Each of frames 2002 and 2006 is configured to surround only the boundary or perimeter or edge 2016 of insulation device 2004, and thus has a hollow center 2008. Insulation device 2004 fills hollow center 2008. Each of frames 2002 and 2006 has a shape (rectangular in this case) that corresponds to the shape of edge 2016 of insulation device 2004 (insulation device 2004 is rectangular in shape in this case).

[0262] The framing apparatus may include a tape and / or adhesive applicator for applying tape and / or adhesive. The adhesive 2010 may be applied to one side of only the frame 2002 or 2006, or may be applied to one side of both the frames 2006 and 2002. Then, in a first scenario, one or more sides of the lower frame 2002 and / or the upper frame 2006 on which the adhesive 2010 has been applied can be attached to the edge 2016 of the insulation device 2004, or in a second scenario, the side of the lower frame 2002 or the upper frame 2006 on which the adhesive 2010 has been applied is attached to the side of the other frame 2006 or 2002, respectively. The second scenario may be applied when the bag is thick and the upper frame 2006 cannot contact the lower frame 2002 when the two frames are placed on the bag.

[0263] In another example, adhesive 2010 may be in the form of a tape, such as double-sided tape or transfer tape, that is applied to edge 2016 of insulation device 2004 or frames 2002 and / or 2006 before the three framing process steps described with reference to Figure 20 are performed. In this case, the intermediate bonding step may include the additional process step of removing or peeling off a release liner 2014 present on adhesive tape 2010 that is applied to one or both of frames 2002 and 2006 or that is applied to edge 2016 of insulation device 2004.

[0264] The framing apparatus may include a control station with one or more processors or controllers that control the process. The control station may have a display that displays a graphical user interface for user control and configuration. The display may be a touchscreen display. The control station may include indicator lights that indicate whether the apparatus is operating, in various stages of operation, or is non-functional. The control station may include multiple user interfaces, such as buttons, knobs, switches, etc., for controlling the apparatus. The apparatus includes one or more motors or engines and a power source for driving its moving parts.

[0265] After the framing process described with reference to Figures 20 and 20A, degassing can be performed. This is step 1706 in Figure 17. The degassing process can be performed by an example degassing conveyor device / system described below. This degassing conveyor system does not provide heating. Degassing step 1706 can also be performed by a method and device similar to that described with reference to Figures 12-12B, and if heating is not required, it is not necessary to use a module of the device 1200 that provides heating.

[0266] The purpose of degassing is to remove excess air from inside each bag of the insulation device and to help secure the frame of each bag. FIG. 21 shows an example of a degassing conveyor apparatus / system 2100 including two conveyors positioned one on top of the other: an upper conveyor 2102 and a lower conveyor 2104. The upper (or upper) conveyor includes multiple interconnected upper plates 2106 (also referred to as upper conveyor plates) arranged to move in an endless loop, and the lower (or lower) conveyor 2104 (also referred to as lower conveyor plates) includes multiple interconnected lower plates 2108 arranged to move in an endless loop. The distance between both the conveyors 2102 and 2104 is adjustable. In this example, each upper plate 2106 cooperates with the lower plate 2108 to compress the framed bags (or, in another example, unframed bags) of the insulation device positioned between them to degas the framed bags. The speeds of both conveyors 2102 and 2104 must be synchronized. This can be accomplished by either mechanical and / or electrical synchronization methods.

[0267] For example, framed bags (or frameless bags in another example) to be evacuated may be placed on the lower conveyor 2104 by the lower plate 2110. The direction of the bags transported by the lower conveyor 2104 is indicated by the large, bold arrow in FIG. 21. The size of each lower conveyor plate 2108 may be larger than the actual framed or frameless bags, so that each bag can be placed within the footprint of the lower conveyor plate 2108.

[0268] The following description refers to both Figures 21A and 21B. Figure 21A shows a bottom perspective view of one of the upper plates 2106. Figure 21B shows a top perspective view of the upper plate 2106. In Figures 21A and 21B, the outer wall 2126 of the upper portion 2120 of the upper plate 2106 is intentionally depicted as transparent to show the rear portion of the outer wall 2126. The lower base 2118 of the upper plate 2106 is shown at the top in Figure 21A and at the bottom in Figure 21B. The upper plate 2106 is configured to facilitate degassing of each bag present within the lower conveyor plate 2108 via vacuum suction. The lower base 2118 of the upper conveyor plate 2106 is perforated with a plurality of perforations 2112 and is connected to a vacuum suction unit (or vacuum suction device) 2114 to draw or suck air through the perforations 2112. When the upper conveyor plate 2108 is positioned over the bags in the lower conveyor plate 2108, vacuum suction is used to evacuate the bags in the lower conveyor plate 2106. The vacuum suction unit 2114 includes an air pump that provides suction, and an air suction pipe 2116 connects the vacuum suction unit 2114 to the lower base 2118.

[0269] The upper portion 2120 of the top plate 2106 is configured with a pushing mechanism comprising one or more cams 2122, i.e., linear cams located at the four corners, and a spring set including one or more biasing members. Each linear cam 2122 is in the form of a roller. In this example, the biasing member(s) are a plurality of springs 2124 that are used to set the required compression and force on a bag placed between the top plate 2106 and the bottom plate 2108 (not shown in FIG. 21B ). During operation, the one or more cams 2122 are pressed together to compress the springs 2124, which in turn apply further pressure to the lower base 2118a in contact with the bag.

[0270] FIG. 21C shows a simplified cross-sectional side view of the upper plate 2106 of FIGS. 20A and 20B. FIG. 21C also shows the lower plate 2108, with the framed bag 2130 of the insulation device positioned between the lower base 2118 of the upper plate 2106 and the lower plate 2108. During degassing, vacuum is applied via the vacuum suction unit 2114 and air suction pipe 2116. Air is drawn from the lower base 2118 through the perforations 2112, through the upper portion 2120 of the upper plate 2106, through the pipe 2116, and toward the air pump of the vacuum suction unit 2114. The perforations 2112 are configured so that they are within the frame dimensions of the framed bag 2130. This ensures proper vacuum suction into the bag. In FIG. 21C, a small arrow indicates the direction of air being drawn in as the framed bag 2130 is degassed. The large, bold arrow indicates the direction of pressure applied from the upper plate 2106 towards the lower plate 2108 to compress the framed bag 2130 to a predetermined frame height.

[0271] FIG. 21D shows a partially see-through close-up view of the upper conveyor 2102 and the lower conveyor 2104. Movement of the multiple interconnected upper plates 2106 is driven by two or more sprocket wheels 2132 (one shown in FIG. 21D and the other located at the opposite end of the upper conveyor 2102). A motor or engine (not shown) is used to drive and move the sprocket wheels 2132. The upper conveyor 2102 comprises an upper row 2136 of interconnected upper plates 2106 and a lower row 2138 of interconnected upper plates 2106. Only the lower row 2138 of interconnected upper plates 2106 cooperates with the lower conveyor 2104 to degas and compress the bags.

[0272] The force applied to the framed bag 2130 between the upper plate 2106 and the lower plate 2108 is applied to a linear cam 2122 through one or more guides, such as two rows of adjustable roller guides 2134 mounted on two opposing left and right sides of the upper conveyor 2102. FIG. 21D shows the left row of adjustable roller guides 2134. A wheel 2132 drives the upper plate 2106, which connects with a lower row 2138, through two substantially parallel rows of adjustable roller guides 2134 (one row is shown in FIG. 21D). Each row of adjustable roller guides 2134 guides a linear cam (roller) 2122 to apply pressure to a plurality of springs 2124. The linear cam thus pushes against the springs, which in turn push against the perforated lower base 2118 of the upper plate 2106.

[0273] The total evacuation time may be defined by the total length of the conveyor and the conveyor speed. If the bag is a framed bag, the length of each upper conveyor plate 2106 and lower conveyor plate 2108 is determined by the length of the frame. The width of the frame defines the width of the conveyor plates 2106 and 2108. If the bag is frameless, the length and width of each upper conveyor plate 2106 and lower conveyor plate 2108 is determined by the length of the insulation device or frame. The width of the frame defines the width of the conveyor plates 2106 and 2108. Thus, in one example, the evacuation time is a function of the total length of the conveyor and the conveyor speed. The length of the conveyor is a function of the length of the insulation device or frame, and the width of the conveyor is also a function of the width of the insulation device or frame.

[0274] 21E shows a side view of a near full length of an example degassing conveyor system 2100. An upper conveyor 2102 and a lower conveyor 2104 are shown.

[0275] As an example, to achieve a degassing time of about 30 seconds at 50 ppm, the conveyor length may be about 8 m.

[0276] Although degassing is described as being performed via vacuum suction through the upper conveyor plate 2106 and pressure is described as being applied via the upper conveyor plate 2106, it should be understood that in another example, such degassing and pressure application may instead be implemented on the lower conveyor plate 2108.

[0277] A computer / control system, which may have one or more processors / controllers and one or more displays (i.e., monitors (e.g., based on LCD, LED, OLED, etc.), touch screens, etc.) that display a graphical user interface for user control and / or one or more user input / output interfaces (buttons, mouse, keyboard, etc.), may be connected to the degassing conveyor apparatus / system 2100 to provide control over moving parts (e.g., adjusting positioning, adjusting orientation, switching on / off, etc.), control over sensors (e.g., photocells), and control over process parameters (e.g., line speed, pressure, temperature, etc.) in the degassing conveyor apparatus / system 2100.

[0278] Regarding the framed bag (e.g., 2130 in FIG. 21C), it is an ultra-thin fire-resistant (FR) sheet that responds quickly to high temperatures and flames, and can be combined with a flame-retardant device similar to the fire-resistant device described above, and inserted into the framed insulation device that has been evacuated according to step 1706 in FIG. 17 above, or inserted before the evacuating step 1706 in FIG. 17.

[0279] An example of a flame-retardant device may have the following thermal expansion characteristics: it can respond quickly at temperatures above 175 degrees Celsius, it can expand to five times its original thickness, it can fill voids to create 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 13a and 13b below for details of this example of a flame-retardant device.

[0280] [Table 15]

[0281] [Table 16]

[0282] 16A, the intent of the insertion process is to attach a flame retardant device 1602 to each side of an opening defined by each upper and lower frame layer 1604 of the frame structure of framed insulation device 1600a. The dimensions of flame retardant device 1602 must be within the size of the opening defined by each frame layer 1604. After insertion of the flame retardant device, the surface of the flame retardant device should preferably be immediately sealed with sealant 1606.

[0283] In one example, the flame retardant device may be angular or rectangular in shape to fit into a corresponding angular or rectangular opening defined by the upper or lower frame layers used to frame the insulation device.

[0284] 22 illustrates an example of an assembly process for a framed insulation device including the flame retardant device 2204 described above. A top view of a framed insulation device 2202 and an unsealed framed insulation device 2212 containing the flame retardant device 2204 is shown. The input to this assembly process is a framed insulation device 2202 having an opening 2206 exposing the insulation device 2200 disposed between an upper frame layer 2208 and a lower frame layer 2210.

[0285] An assembly machine can be used for an assembly process. The machine can include a control station with one or more processors or controllers that control the process. The control station can have a display that displays a graphical user interface for user control and configuration. The display can be a touchscreen display. The control station can include indicator lights that indicate whether the machine is operating, in various stages of operation, or is non-functional. The control station can include multiple user interfaces, such as buttons, knobs, switches, etc., for controlling the machine. The machine also includes one or more motors or engines and a power source for driving its moving parts.

[0286] In a first step, a first flame retardant device 2204 is placed in a first opening 2206 in either the upper frame layer 2208 or the lower frame layer 2210. The first flame retardant device 2204 contacts the insulation device 2100 after being inserted.

[0287] In a second step, the top or bottom major surface of the framed insulation device 2202 is sealed to secure the first flame retardant device 2204 within the first opening 2206. The sealing process is described in further detail below. The sealing step is not shown in Figure 22.

[0288] In a third step, the framed insulating device 2202 is inverted. The reference numbers of the first flame retardant device 2204 and the first opening 2206 are reused for the second flame retardant device and second opening, respectively, which are described below.

[0289] In a fourth step, second flame retardant device 2204 is inserted into second opening 2206 in either lower frame layer 2210 or upper frame layer 2208. After insertion, second flame retardant device 2204 contacts insulation device 2200.

[0290] In a fifth step, the bottom or top surface of each of the framed insulation devices 2202 is sealed to secure the second flame retardant device 2204 within the second opening 2206. The sealing process is described in further detail below. The sealing step is not shown in Figure 22.

[0291] The flame retardant device 2204 may be supplied from a bulk roll, and a die cutting process may be required to cut the flame retardant device 2204 to the correct size prior to the assembly process.

[0292] Additionally, the flame retardant device 2204 may be provided from two or more flame retardant devices stacked on top of one another, in which case a release liner may be provided between the two or more layers of the flame retardant devices to prevent the two or more flame retardant devices from sticking to one another, which would affect the picking up of each flame retardant device 2202 for insertion into the opening 2206 in the upper frame layer 2208 or lower frame layer 2210 of the framed insulation device 2204.

[0293] Optionally, the inserted flame retardant device 2204 may be adhered to the exposed surface of the insulation device 2202 at an opening 2206 in the upper frame layer 2208 or the lower frame layer 2210 of the framed insulation device 2100 .

[0294] A pick-and-place robot may be used to insert each flame retardant device 2204 into an opening 2206 defined by frame layer 2208 or 2210 of framed insulation device 2202. A vacuum gripper may be considered for picking.

[0295] In the above example, only one flame retardant device 2204 is featured and described as being placed within each opening exposing the insulation device 2200, however, it should be understood that two or more flame retardant devices may be stacked and placed within each opening to improve effectiveness.

[0296] The sealing step 1710 in Figure 17 will now be described with reference to Figures 22 and 22A. Figure 22A shows a side cross-sectional view of a sealed framed insulation device 2214, a top view of a seal being applied to the framed insulation device 2212, and a top view of the sealed framed insulation device 2214. After insertion of the first flame retardant device 2204, the surface with the inserted first flame retardant device 2204 is sealed, and then the framed insulation device 2212 is inverted to insert the second flame retardant device 2204. A sealing layer 2216 is applied over the framed insulation device 2212 containing the inserted first flame retardant device 2204. After the framed insulation device 2212 is inverted and the second flame retardant device 2204 is inserted, another sealing layer 2216 is applied over the surface of the framed insulation device 2212 into which the second flame retardant device 2204 was inserted. After sealing is complete, a sealed, framed insulation device 2214 is obtained, containing the insulation device 2200 between the two flame retardant devices 2204 and the two frame layers 2208 and 2210 .

[0297] A label (or seal) applicator is a piece of equipment that may be 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 one example, two applicators may be used to seal both sides of a framed insulation device together. FIG. 22B shows an example of a label applicator 2220. The label applicator 2220 includes one or more spooling devices 2218 for attaching one or more bulk rolls of sealant. A plurality of guides 2222 are provided to guide the sealant from the bulk roll toward a seal applicator 2224, which has a cutter that cuts the sealant after the applied seal sufficiently covers the framed insulation device. Sealing can be performed immediately after framing, even without inserting a flame-retardant device.

[0298] The assembly apparatus described above may be configured to perform the sealing process described above, and may include a pick-and-place robot and the label (or seal) applicator described above.

[0299] Quality checks may be performed at various stages of steps 1702-1710 in FIG. 17. One quality criterion is that the correct amount of material (powder) must be filled inside each framed or frameless bag of the insulation device. An in-line checkweigher may be used to identify bags containing an incorrect amount of material. See FIG. 23 for an example of such a checkweigher 2300. The checkweigher 2300 includes a fixture or platform 2302 on which the bags to be weighed are placed and a control unit 2304 that controls the quality weight check process. Another example of a checkweigher 2300 is the apparatus 600 shown in FIGS. 6-6B. The checkweigher 2300 may be located immediately after the bag filling machine, i.e., bags exiting the machine are weighed. Bags with incorrect weights may be rejected and rejected before downstream processes begin. Weight checks may also be performed immediately after other steps, such as steps 1702-1710 in FIG. 17. After each step in FIG. 17, a check involving computer vision to detect defects may also be performed.

[0300] If line speed is a concern, a two-lane checkweigher (using two lanes to weigh bags instead of one) can be used to speed up checkweighing. Additional lanes can be added as needed.

[0301] The checkweigher 2300 may include a control station with one or more processors or controllers that control the process. The control station may have a display that displays a graphical user interface for user control and configuration. The display may be a touchscreen display. The control station may include indicator lights that indicate whether the checkweigher 2300 is operating, in various stages of operation, or is not functioning. The control station may include multiple user interfaces, such as buttons, knobs, switches, etc., for controlling the checkweigher 2300. The checkweigher 2300 includes one or more motors or engines and a power source for driving its moving parts.

[0302] In another example, steps for attaching a frame to a bag of insulation device 2400 and sealing the frame are described below with reference to Figures 24 and 24A. In this example, the bag of insulation device 2400 is sealed with a three-sided seal and has three sealed areas 2402. It should be understood that in another example, a four-sided sealed bag may be used, if desired. These three sealed areas 2402 include first and second horizontal seal areas having a length equal to the width of bag 2400, which are located at opposing edges of bag 2400. A third center seal is perpendicular to the first and second horizontal seal areas.

[0303] First, the insulating device 2400 is inserted into a main opening 2406 in a single-piece frame structure 2404 (e.g., a silicone frame) to form the framed insulating device 2400. Second, electrically insulating film layers 2406 are added or placed completely or partially over the major surfaces of the framed insulating device 2400. Heat and pressure are passed through these film layers 2406 to heat them and soften and / or melt them to form a seal.

[0304] When a framed and sealed combination of insulating device and flame retardant device (e.g., 1600a in FIG. 16A) is made using the framing and sealing process described above, the described insulating device 2400 can be replaced with an insulating device bonded to two flame retardant device layers (e.g., 1602 in FIG. 16A).

[0305] Examples of the present disclosure may have the following features: Reference numbers in parentheses refer to the reference numbers of elements in the figures.

[0306] 1. A method of manufacturing an insulating device (e.g., 100, 1500, 1608, 1800, 1804, 1900, 2004, 2200, 2400, 2500, 2510, 2520, 2530), comprising: forming a bag (e.g., 100, 400, 410, 522, 532, 808, 900, 1010, 2500, 2510, 2520, 2530, 1110, 1804, 1900, 2130, 2400) from a film material (e.g., FML1, FML2, FML3, FF4, 406, 1800) including perforations (e.g., 1802); Filling the bag with insulating particles (e.g., FF1, FF2, and FF3) having a size that will not pass through the perforations; sealing one or more sides of the bag (e.g., 904, 906, 2538, 2016, 1904) to prevent insulating particles from exiting through the one or more sides of the bag; After the open side of the bag for filling with insulating particles is sealed, the bag is compressed to remove the gas contained in the bag. The method may optionally further include heating the bag as it is compressed, and optionally cooling the bag as it is compressed. In another example, there may be two or more open sides of the bag for filling with insulating particles.

[0307] The method comprises: applying tape and / or adhesive (e.g., 902) to a portion of one or more sealed sides (e.g., 904, 906) of the bag; Folding one or more sealed sides of the bag and adhering the taped and / or adhesive portions to the body of the bag (e.g., step 226); may include:

[0308] The method may include passing the bag and one or more sealed sides through a plurality of roller sets (e.g., 1012, 1014, 1016, 1018, 1020, 1022, 1024) to fold the one or more sealed sides of the bag and adhere the taped and / or adhesive portion to the body of the bag (e.g., step 228), including a roller set configured with an angled incline to guide the one or more sealed sides to fold toward the body of the bag.

[0309] The method may include scoring fold lines in one or more sealed sides of the bag prior to folding the one or more sealed sides.

[0310] The method may include folding one or more corners (e.g., 804) of the bag (e.g., step 224) before folding one or more sealed sides of the bag and adhering the taped and / or adhesive-applied portion to the body of the bag.

[0311] The insulating particles may comprise a mixture of particles from two or more types of materials, and the method may further comprise: transferring particles of two or more types of materials into different containers (e.g., 302, 304a, 306a) separated by type of material; Weighing each container (e.g., 304a, 306a); Distributing particles of each type of material from each container simultaneously into a mixing container (e.g., 308a, 310); and dispensing of particles from each container (e.g., 304a, 306a) is stopped when the weight of each container reaches a predetermined weight (e.g., steps 206, 208, and 210). Dosing system B of Figure 3A is one example of implementing these method steps.

[0312] In another example, the insulating particles may include a mixture of particles from two or more types of materials, and the method may further include: transferring particles of two or more types of materials into different containers (e.g., 302, 304b, 306b) separated by type of material; Distributing particles of each type of material from each container (e.g., 304b, 306b) into a mixing container (e.g., 308b); Weighing the mixing vessel and dispensing of particles is stopped when the weight of the mixing vessel reaches a predetermined weight (e.g., steps 206, 208, and 210). Dosing system C of Figure 3A is one example of implementing these method steps.

[0313] The particles in the mixing vessel (e.g., 308a, 310) can be homogenously mixed and transferred to two or more reservoirs (e.g., 316, 318), each reservoir being considered one batch of mixed particles, and the mixed particles being transferred in batches to fill multiple bags.

[0314] The method comprises: Providing two or more layers of film and / or fabric (e.g., 1 and 2 in FIG. 19); applying pressure and heat to two or more layers of film and / or fabric to form a film material; perforating the film material to form perforations; may include:

[0315] The method comprises: providing a film material to form a bag; sealing the film material to form one or more sealed sides of the bag, while leaving one side of the bag unsealed; filling the bag with insulating particles through the unsealed side; After the bag has been filled with insulating particles, sealing the unsealed side of the bag (e.g., step 218) Examples of these steps are described with reference to Figures 5 and 19.

[0316] The method comprises: placing the bag between two plates (e.g., plates of an MLHP-based device, plate 1206 of a module for pressure and heating), the distance between the plates being adjustable to apply or release pressure to the bag and degas it; heating the plate to provide a heat treatment to the bag when pressure is applied to the bag (e.g., step 232); may include:

[0317] The method may include cooling the plate to cool the bag when pressure is applied to the bag (eg, step 232).

[0318] The method may include placing (e.g., step 232) a bag on a dual belt press conveyor (e.g., 1200) comprising a first endless belt (e.g., 1226) and a second endless belt (e.g., 1228), wherein the bag is positioned between the first and second endless belts and transported along the length of both the first and second endless belts through synchronous movement of the first and second endless belts, and the distance between the first and second endless belts is adjustable to apply or release pressure to the bag.

[0319] A first piece of fabric may be present between the first endless belt and the bag, and a second piece of fabric may be present between the second endless belt and the bag, and the method includes imprinting a pattern provided by the first piece of fabric and / or the second piece of fabric into the bag when pressure is applied to the bag by the first endless belt and the second endless belt, respectively.

[0320] The surface of the first endless belt that contacts the bag may be coated, and the surface of the second endless belt that contacts the bag may be coated, and the method may include imprinting a pattern on the bag that is provided by one or both of the coated surfaces of the first endless belt and the second endless belt when pressure is applied to the bag by the first endless belt and the second endless belt, respectively.

[0321] The method may include heating the first endless belt and / or the second endless belt to provide a heat treatment to the bag as pressure is applied to the bag by the first endless belt and the second endless belt (step 232).

[0322] The method comprises: gradually increasing the temperature of the first endless belt and / or the second endless belt in a direction in which the bag is transported by the first endless belt and / or the second endless belt to heat the bag while maintaining pressure on the bag; applying a predetermined maximum pressure to the bag when the temperature rises near or is at the predetermined maximum temperature (step 232); may include:

[0323] The method may include cooling the first and / or second endless belts to cool the bag when pressure is applied to the bag by the first and second endless belts (step 232).

[0324] The method may include gradually reducing the temperature of the first endless belt and / or the second endless belt in a direction in which the bag is transported by the first endless belt and / or the second endless belt to a predetermined cooling temperature to cool the bag while maintaining pressure on the bag (step 232).

[0325] The method comprises: Cleaning the bag after the insulating particles have been sealed within the bag and before compressing the bag to remove any gas entrapped therein (step 222); After the bag has cooled, cleaning the bag (step 234) may include:

[0326] The method may include applying tape and / or adhesive (e.g., 1408a, 1410a, 1412a, 1414a, and 1414b) to the bag to enable the bag to be adhered to another object (e.g., step 238), with a release liner provided over the applied tape and / or adhesive.

[0327] The method comprises: Stacking two or more bags (e.g., 1500) on a bottom plate (e.g., 1504) and stacking a top plate (e.g., 1506) on top of the topmost stacked bag; tying a bundle including the bottom plate, the top plate, and the bag stacked between the bottom plate and the top plate with a strap; may include:

[0328] The method comprises: Adhering the bag to a first frame layer (e.g., 1604, 2006, 2208); Adhering a second frame layer (e.g., 1604, 2002, 2210) onto the bag to form a framed bag (e.g., 1600a, 1600b, 2130, 2214, 2400) including the first frame layer and the second frame layer as a frame structure; may include:

[0329] The method can include adhering a single piece frame structure (eg, 2404) to a bag to form a framed bag (eg, 1600a, 1600b, 2130, 2214, 2400).

[0330] The method comprises: inserting a first layer (e.g., 1602, 2204) of a flame retardant device into a first opening of a frame structure (e.g., 1604, 2006, 2208, 2404) to cover an exposed surface of the bag; inserting a second layer of flame retardant device (e.g., 1602, 2204) into a second opening in the frame structure to cover another exposed surface of the bag; may include:

[0331] The method comprises: sealing a first exterior side of the framed bag; sealing the second outer side of the framed bag; wherein the second outer side is opposite the first outer side.

[0332] The method may include degassing the bag by drawing air from the bag using vacuum suction.

[0333] The method may include weighing the bags after they are sealed and filled, and if the weight of the bags is near or beyond the limits of an acceptable weight range, a feedback data signal to adjust the dosage may be electronically communicated to increase or decrease the dosage of insulating particles filled into each bag. For example, the apparatus 600 of FIG. 6 may be equipped with such feedback control to cooperate with the apparatus 400 of FIG. 4 to adjust the dosage in real time.

[0334] The method may include vibrating the bag to level the insulating particles packed within the bag during or before compressing the bag to remove any gas contained therein.

[0335] The method may include placing a framed or frameless version of a bag (e.g., 2130, 1500) between an upper conveyor plate (e.g., 2106) of a plurality of upper conveyor plates and a lower conveyor plate (e.g., 2108) of a plurality of lower conveyor plates, the upper conveyor plate being configured to apply pressure to the framed or frameless bag between the upper and lower conveyor plates to degas the framed or frameless bag.

[0336] The upper or lower conveyor plate may include one or more biasing members (eg, 2124) to facilitate the release of pressure acting on the framed or frameless bag.

[0337] The upper or lower conveyor plate may include a pushing mechanism including one or more cams (e.g., 2122) attached to the upper or lower conveyor plate, and the method may include moving the upper or lower conveyor plate past a plurality of guides (e.g., 2134), which are configured to apply pressure to the one or more cams to press the upper or lower conveyor plate against the bag, thereby applying pressure to the bag between the upper and lower conveyor plates.

[0338] The upper or lower conveyor plate may include perforations (e.g., 2112) for contacting and degassing the bag, and the method includes drawing air through the perforations in contact with the bag to degas the bag.

[0339] 1. A system for manufacturing an insulating device (e.g., 100, 1500, 1608, 1800, 1804, 1900, 2004, 2200, 2400, 2500, 2510, 2520, 2530), comprising: a forming tool (e.g., 528, 1910, 8-18 in Figure 19) for forming a bag (e.g., 100, 400, 410, 522, 532, 808, 900, 1010, 2500, 2510, 2520, 2530, 1110, 1804, 1900, 2130, 2400) from a film material (e.g., FML1, FML2, FML3, FF4, 406, 1800) including perforations (e.g., 1802); a filling machine (e.g., 400, 404, 502, and 22 and 23 in FIG. 19) for filling the bag with insulating particles (e.g., FF1, FF2, and FF3) having a size that does not pass through the perforations; one or more sealers (e.g., 514, 518 and 10, 11, 12, 25 and 26 of FIG. 19) for sealing one or more sides of the bag (e.g., 904, 906, 2538, 2016, 1904) to prevent insulating particles from exiting through the one or more sides of the bag; a compression device (e.g., 1200, 2100) for compressing the bag after the open side of the bag for filling with insulating particles is sealed to remove gas contained in the bag; The system may optionally further comprise a heater (e.g., 1206a, 1206b, 1206c, 1206d, 1206e, 1212, 1214) that heats the bag as it is compressed, and optionally a cooler (e.g., 1208, 1208a) that cools the bag as it is compressed. In another example, there may be two or more open sides of the bag for filling with insulation particles.

[0340] This system is a tape and / or adhesive applicator (e.g., 908) for applying tape and / or adhesive (e.g., 902) to a portion of one or more sealed sides (e.g., 904, 906) of the bag; a folding device (e.g., 1000) for folding one or more sealed sides of the bag and adhering the taped and / or adhesive-applied portion to the body of the bag; It may comprise:

[0341] The folding device may include a conveying device (e.g., 1001) for passing the bag and one or more sealed sides through a plurality of roller sets (e.g., 1012, 1014, 1016, 1018, 1020, 1022, 1024) to fold the one or more sealed sides of the bag and adhere the taped and / or adhesive portion to the body of the bag, including a roller set configured with an angled incline to guide the one or more sealed sides to fold toward the body of the bag.

[0342] The plurality of roller sets may include a roller set (e.g., 1012) configured to score fold lines in one or more sealed sides of the bag prior to folding of the one or more sealed sides.

[0343] The folding device may be configured to fold one or more corners (e.g., 804) of the bag before folding one or more sealed sides of the bag and adhering the taped and / or adhesive-applied portion to the body of the bag.

[0344] The insulating particles may include a mixture of particles from two or more types of materials, and the system may include: different containers (e.g., 302, 304a, 306a) for receiving particles of two or more types of materials, the different containers being sorted by material type; a weighing device (e.g., load cell D) for weighing each container (e.g., 304a, 306a); a dispenser (e.g., 304a and 306a configured to dispense) for dispensing particles of each type of material from each container simultaneously into a mixing container (e.g., 308a, 310); and dispensing of particles from each container (e.g., 304a, 306a) is stopped when the weight of each container reaches a predetermined weight. Dosing system B of Figure 3A is an example described by these features.

[0345] The insulating particles may include a mixture of particles from two or more types of materials, and the system may include: different containers (e.g., 302, 304b, 306b) for receiving particles of two or more types of materials, the different containers being sorted by material type; a dispenser for dispensing particles of each type of material from each container (e.g., 304b, 306b) into a mixing container (e.g., 308b); a weighing device (e.g., load cell D) for weighing the mixing vessel; and dispensing of particles is stopped when the weight of the mixing vessel reaches a predetermined weight. Dosing system C of Figure 3A is an example described by these features.

[0346] With this system, particles in a mixing vessel (e.g., 308a, 310) can be homogenously mixed and transferred to two or more reservoirs (e.g., 316, 318), each reservoir being considered one batch of mixed particles, and the mixed particles being transferred in batches to fill multiple bags.

[0347] This system is a feeder (e.g., 406, 506, 524, 1-4 in FIG. 19) for feeding two or more layers of film and / or fabric; a pressure and heating device for applying pressure and heat to two or more layers of film and / or fabric to form a film material; a perforation punch (e.g., 5 in FIG. 19) for perforating the film material to form perforations; Examples of these steps are described with reference to Figures 5 and 19.

[0348] The system may include a feeder (e.g., 406, 506, 524, 1-7 in FIG. 19) for feeding film material to form bags; one or more sealers (e.g., 514, 518 and 10, 11, 12, 25, and 26 in FIG. 19) configured to seal the film material to form one or more sealed sides of the bag, while leaving one side of the bag unsealed; the filler is configured to fill the insulating particles through the unsealed side of the bag; One of the one or more sealers (e.g., 518, 25 and 26 in FIG. 1) is configured to seal the unsealed side of the bag after filling of the bag with insulating particles is complete.

[0349] This system is a plurality of plates (e.g., plates of an MLHP-based device, plates 1206 of a pressure and heating module) for receiving one or more bags between two plates of the plurality of plates, the distance between the plates being adjustable to apply or release pressure to the bags to degas them; a heating element for heating the plate to provide a heat treatment to the bag when pressure is applied to the bag; It may comprise:

[0350] The system may include a cooler (eg, 1208, 1208a) that cools the plate and cools the bag when pressure is applied to the bag.

[0351] The system may include a dual belt press conveyor (e.g., 1200) including a first endless belt (e.g., 1226) and a second endless belt (e.g., 1228), wherein the bag is positioned between the first and second endless belts and transported along the length of both the first and second endless belts through synchronous movement of the first and second endless belts, and the distance between the first and second endless belts is adjustable to apply or release pressure to the bag.

[0352] With respect to this system, a first piece of fabric may be present between the first endless belt and the bag, and a second piece of fabric may be present between the second endless belt and the bag, and the first piece of fabric and / or the second piece of fabric imprint a pattern on the bag when pressure is applied to the bag by the first endless belt and the second endless belt, respectively.

[0353] With this system, the surface of the first endless belt that contacts the bag may be coated, and the surface of the second endless belt that contacts the bag may be coated, with one or both of the coated surfaces imprinting a pattern into the bag when pressure is applied to the bag by the first endless belt and the second endless belt, respectively.

[0354] The system may include one or more heaters (e.g., 1206a, 1206b, 1206c, 1206d, 1206e, 1212, 1214) for heating the first endless belt and / or the second endless belt to provide a thermal treatment to the bag when pressure is applied to the bag by the first endless belt and the second endless belt.

[0355] This system is two or more heaters (e.g., 1206a, 1206b, 1206c, 1206d, 1206e, 1212, 1214) disposed along the first and second endless belts for gradually increasing the temperature of the first and / or second endless belts in a direction in which the bags are transported by the first and / or second endless belts to heat the bags while maintaining pressure on the bags; a heating and compression module (e.g., 1206b, 1206e) for applying a predetermined maximum pressure to the bag when the temperature rises near or is at a predetermined maximum temperature; It may comprise:

[0356] The system may include one or more coolers (e.g., 1208, 1208a) for cooling the first endless belt and / or the second endless belt to cool the bag when pressure is applied to the bag by the first endless belt and the second endless belt.

[0357] The system may include two or more coolers (e.g., 1208, 1208a) positioned along the first endless belt and / or the second endless belt to gradually reduce the temperature of the first endless belt and / or the second endless belt to a predetermined cooling temperature in the direction in which the bags are transported by the first endless belt and / or the second endless belt, thereby cooling the bags while maintaining pressure on the bags.

[0358] This system is cleaning the bag after the insulating particles are sealed within the bag and before compressing the bag to remove any gas entrapped therein; After the bag has cooled, clean the bag and The cleaning device may be provided for performing the above.

[0359] The system may include a tape and / or adhesive applicator for applying tape and / or adhesive (e.g., 1408a, 1410a, 1412a, 1414a, and 1414b) to the bag to enable the bag to be adhered to another object, with a release liner provided over the applied tape and / or adhesive.

[0360] This system is a first pick and place device for stacking two or more bags (e.g., 1500) on a bottom plate (e.g., 1504) and stacking a top plate (e.g., 1506) on top of the topmost stacked bag; a tying device for tying a bundle including a bottom plate, a top plate, and a bag stacked between the bottom plate and the top plate; It may comprise:

[0361] This system is a platform for holding a first frame layer (e.g., 1604, 2006, 2208); a second pick and place device, moving the bag and adhering the bag onto the first frame layer; Moving the second frame layer and adhering the second frame layer (e.g., 1604, 2002, 2210) onto the bag to form a framed bag (e.g., 1600a, 1600b, 2130, 2214, 2400) including the first frame layer and the second frame layer as a frame structure. and a second pick-and-place device for It may comprise:

[0362] The system may include a third pick and place device for moving a single piece frame structure and adhering the single piece frame structure (e.g., 2404) to a bag to form a framed bag (e.g., 1600a, 1600b, 2130, 2214, 2400).

[0363] This system is inserting a first layer (e.g., 1602, 2204) of a flame retardant device into a first opening (e.g., 2008, 2206, 2406) of a frame structure (e.g., 1604, 2006, 2208, 2404) to cover an exposed surface of the bag; inserting a second layer (e.g., 1602, 2204) of the flame retardant device into a second opening (e.g., 2008, 2206, 2406) in the frame structure to cover another exposed surface of the bag; a fourth pick-and-place device for performing the steps of:

[0364] This system is sealing a first exterior side of the framed bag; sealing the second outer side of the framed bag; wherein the second outer side is opposite the first outer side.

[0365] The system may include a vacuum suction device (eg, 2114) for degassing the bag by drawing air from the bag using vacuum suction.

[0366] The system may include a weighing device (e.g., 600, 2300) for weighing the bags after they are sealed and filled, and if the weight of the bag is near or beyond the limits of an acceptable weight range, a feedback data signal for adjusting the powder dosage is electronically communicated to increase or decrease the dosage of insulating particles filled into each bag.

[0367] The system may include a vibration device (e.g., 1204) for vibrating the bag to level the insulating particles packed within the bag during or before compressing the bag to remove the gas contained therein.

[0368] This system is an upper conveyor (e.g., 2102) including a plurality of upper conveyor plates; a lower conveyor (e.g., 2104) including a plurality of lower conveyor plates; and a framed or frameless version of the bag (e.g., 2130, 1500) is positioned between an upper conveyor plate (e.g., 2106) of the plurality of upper conveyor plates and a lower conveyor plate (e.g., 2108) of the plurality of lower conveyor plates; The upper conveyor plate is configured to apply pressure to the bag between the upper and lower conveyor plates to evacuate the framed or frameless bag.

[0369] With the present system, the upper or lower conveyor plate may include one or more biasing members (eg, 2124) to facilitate the release of pressure acting on the framed or frameless bag.

[0370] For this system, the upper or lower conveyor plate may include a pushing mechanism that includes one or more cams (e.g., 2122) attached to the upper or lower conveyor plate, and a plurality of guides (e.g., 2134) for applying pressure to the one or more cams to press the upper or lower conveyor plate against the bag, thereby applying pressure to the bag between the upper and lower conveyor plates.

[0371] With this system, the upper or lower conveyor plate may include perforations (e.g., 2112) for contacting and degassing the bag, and the perforations are fluidly connected to a vacuum suction device (e.g., 2114) operable to draw air through the perforations.

[0372] All of the equipment described in this disclosure, including 400, 600, 800, 1000, 1200, 1300, 2100, stacking and / or packaging equipment, cleaning equipment, framing equipment, assembly equipment that inserts and seals the FR devices, and / or 2300, may have individual control stations as described. Some or all of these equipment, regardless of whether they interact or are linked to one another, can all be said to be part of a manufacturing system that produces insulation devices according to examples of the present disclosure. In another example, there may be fewer control stations, or only one control station, that control all processes as described. Data communication between the control station, computer vision system, and / or test system, or between sensors and the control station, may be wired or wireless. Necessary electrical cables and / or transceivers are provided for this purpose.

[0373] In this disclosure, unless the context clearly indicates otherwise, the term "comprise" has the non-exclusive meaning of the word in the sense of "comprising 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.

[0374] While this disclosure has described the invention with reference to 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 method of manufacturing a thermal insulation device, comprising: forming a bag from a film material containing perforations; filling the bag with insulating particles having a size that will not pass through the perforations; sealing one or more sides of the bag to prevent the insulating particles from exiting through the one or more sides of the bag; compressing the bag after the open side for filling the insulating particles has been sealed to remove any gas contained in the bag; heating the bag as it is compressed; cooling the bag as it is compressed; A method comprising:

2. applying tape and / or adhesive to a portion of the one or more sealed sides of the bag; folding the one or more sealed sides of the bag and adhering the taped and / or adhesive-applied portions to the body of the bag; The method of claim 1 , comprising:

3. 3. The method of claim 2, comprising passing the bag and the one or more sealed sides through a plurality of roller sets to fold the one or more sealed sides of the bag and adhere the taped and / or adhesive-applied portions to the body of the bag, the plurality of roller sets including a roller set configured with an angled incline to guide the one or more sealed sides to fold toward the body of the bag.

4. 4. The method of claim 3, comprising scoring fold lines in the one or more sealed sides of the bag prior to folding the one or more sealed sides.

5. 5. The method of any one of claims 2 to 4, comprising folding one or more corners of the bag before folding the one or more sealed sides of the bag and adhering the taped and / or adhesive-applied portion to the body of the bag.

6. wherein the insulating particles comprise a mixture of particles from two or more types of materials, and the method further comprises: transferring the particles of the two or more types of materials into different containers separated by the type of material; weighing each container; dispensing said particles of each type of said material from said respective containers simultaneously into a mixing container; and wherein the dispensing of the particles from the respective containers is stopped when the weight of the respective container reaches a predetermined weight.

7. wherein the insulating particles comprise a mixture of particles from two or more types of materials, and the method further comprises: transferring the particles of the two or more types of materials into different containers separated by the type of material; distributing the particles of each type of material from the respective containers into a mixing container; Weighing the mixing vessel; and wherein the dispensing of the particles is stopped when the weight of the mixing vessel reaches a predetermined weight.

8. 6. The method according to claim 4 or 5, wherein the particles in the mixing vessel are mixed homogeneously and transferred to two or more reservoirs, each reservoir being considered as one batch of the mixed particles, and the mixed particles are transferred in batches to fill a plurality of the bags.

9. providing two or more layers of film and / or fabric; applying pressure and heat to two or more layers of the film and / or fabric to form the film material; perforating the film material to form the perforations; The method according to any one of claims 1 to 8, comprising:

10. providing the film material to form the bag; sealing the film material to form the one or more sealed sides of the bag, while leaving one side of the bag unsealed; filling the insulating particles through the unsealed side of the bag; sealing the unsealed side of the bag after the filling of the bag with the insulating particles is complete; The method according to any one of claims 1 to 9, comprising:

11. placing the bag between two plates, the distance between the plates being adjustable to apply or release pressure to the bag to degas the bag; heating the plate to provide a heat treatment to the bag when pressure is applied to the bag; The method according to any one of claims 1 to 10, comprising:

12. 12. The method of claim 11, comprising cooling the plate to cool the bag when pressure is applied to the bag.

13. 11. The method of claim 1, comprising placing the bag on a double belt press conveyor comprising a first endless belt and a second endless belt, wherein the bag is positioned between the first endless belt and the second endless belt and is transported along the length of both the first endless belt and the second endless belt through synchronous movement of the first endless belt and the second endless belt, and the distance between the first endless belt and the second endless belt is adjustable to apply or release pressure to the bag.

14. 14. The method of claim 13, wherein a first piece of fabric is present between the first endless belt and the bag, and a second piece of fabric is present between the second endless belt and the bag, and the method includes imprinting a pattern provided by the first piece of fabric and / or the second piece of fabric into the bag when pressure is applied to the bag by the first endless belt and the second endless belt, respectively.

15. 14. The method of claim 13, wherein a surface of the first endless belt that contacts the bag is coated and a surface of the second endless belt that contacts the bag is coated, the method including imprinting a pattern on the bag provided by one or both of the coated surfaces of the first endless belt and the second endless belt when pressure is applied to the bag by the first endless belt and the second endless belt, respectively.

16. 16. The method according to any one of claims 13 to 15, comprising heating the first endless belt and / or the second endless belt to provide a heat treatment to the bag when pressure is applied to the bag by the first endless belt and the second endless belt.

17. gradually increasing the temperature of the first endless belt and / or the second endless belt in a direction in which the bag is transported by the first endless belt and / or the second endless belt to heat the bag while maintaining pressure on the bag; applying a predetermined maximum pressure to the bag when the temperature rises near or is at a predetermined maximum temperature; 17. The method of claim 16, comprising:

18. 18. The method of claim 16 or 17, comprising cooling the first and / or second endless belts to cool the bag when pressure is applied to the bag by the first and second endless belts.

19. 19. The method of claim 18, further comprising gradually reducing the temperature of the first and / or second endless belts in a direction in which the bag is transported by the first and / or second endless belts to a predetermined cooling temperature to cool the bag while maintaining pressure on the bag.

20. cleaning the bag after the insulating particles are sealed within the bag and before compressing the bag to remove any gas entrapped therein; cleaning the bag after it has cooled; 20. The method of claim 18 or 19, comprising:

21. 21. The method of any one of claims 1 to 20, comprising applying tape and / or adhesive to the bag to enable the bag to be adhered to another object, wherein a release liner is provided over the applied tape and / or adhesive.

22. stacking two or more of the bags on a bottom plate and stacking a top plate on top of the topmost stacked bag; tying a bundle including the bottom plate, the top plate, and the bags stacked between the bottom plate and the top plate with a strap; The method of any one of claims 1 to 21, comprising:

23. Adhering the bag onto a first frame layer; adhering a second frame layer onto the bag to form a framed bag including the first frame layer and the second frame layer as a frame structure; The method of any one of claims 1 to 22, comprising:

24. A method according to any preceding claim, comprising adhering a single piece frame structure to the bag to form a framed bag.

25. inserting a first layer of a flame retardant device into a first opening of the frame structure to cover an exposed surface of the bag; inserting a second layer of a flame retardant device into a second opening in the frame structure to cover another exposed surface of the bag; 25. The method of claim 23 or 24, comprising:

26. sealing a first exterior side of the framed bag; sealing a second outer side of the framed bag; 26. The method of any one of claims 23 to 25, comprising:

27. A method according to any preceding claim, comprising degassing the bag by using vacuum suction to draw air from the bag.

28. 28. The method of any one of claims 1 to 27, comprising weighing the bags after they have been sealed and filled, and if the weight of the bags is close to or exceeds the limits of an acceptable weight range, a feedback data signal to adjust the dosage is electronically communicated to increase or decrease the dosage of insulating particles filled into each bag.

29. The method according to any one of claims 1 to 28, comprising vibrating the bag to level the insulating particles packed in the bag during or before compressing the bag to remove gas contained in the bag.

30. 30. The method of any one of claims 1 to 29, comprising placing a framed or frameless version of the bag between an upper conveyor plate of a plurality of upper conveyor plates and a lower conveyor plate of a plurality of lower conveyor plates, the upper conveyor plate being configured to apply pressure to the framed or frameless bag between the upper and lower conveyor plates to degas the framed or frameless bag.

31. 31. The method of claim 30, wherein the upper conveyor plate or the lower conveyor plate comprises one or more biasing members to facilitate the release of pressure acting on the framed or frameless bag.

32. 32. The method of claim 30 or 31, wherein the upper or lower conveyor plate comprises a pushing mechanism comprising one or more cams attached to the upper or lower conveyor plate, and the method includes moving the upper or lower conveyor plate past a plurality of guides, the plurality of guides configured to apply pressure to the one or more cams to press the upper or lower conveyor plate against the bag, thereby applying pressure to the bag between the upper and lower conveyor plates.

33. 33. The method of any one of claims 30 to 32, wherein the upper or lower conveyor plate includes perforations for contacting and degassing the bag, and the method includes drawing air through the perforations in contact with the bag to degas the bag.

34. 1. A system for manufacturing a thermal insulation device, comprising: a forming tool for forming a bag from the film material containing perforations; a filling machine for filling the bag with insulating particles having a size that does not pass through the perforations; one or more sealers for sealing one or more sides of the bag to prevent the insulating particles from exiting through the one or more sides of the bag; a compression device for compressing the bag after the open side of the bag for filling with the insulating particles has been sealed to remove gas contained in the bag; wherein when the bag is compressed, the bag undergoes heating, and when the bag is compressed, the bag undergoes cooling.

35. a tape and / or adhesive applicator for applying tape and / or adhesive to a portion of the one or more sealed sides of the bag; a folding device for folding the one or more sealed sides of the bag to adhere the taped and / or adhesive-applied portion to the body of the bag; 35. The system of claim 34, comprising:

36. 36. The system of claim 35, wherein the folding device comprises a conveyor for passing the bag and the one or more sealed sides through a plurality of roller sets to fold the one or more sealed sides of the bag and adhere the taped and / or adhesive-applied portion to the body of the bag, the plurality of roller sets including a roller set configured with an angled incline to guide the one or more sealed sides to fold toward the body of the bag.

37. 37. The system of claim 36, wherein the plurality of roller sets includes a roller set configured to score fold lines in the one or more sealed sides of the bag prior to the folding of the one or more sealed sides.

38. 38. The system of any one of claims 35 to 37, wherein the folding device is configured to fold one or more corners of the bag before folding the one or more sealed sides of the bag and adhering the taped and / or adhesive-applied portion to the body of the bag.

39. the insulating particles include a mixture of particles from two or more types of materials, and the system comprises: different containers for receiving the particles of the two or more types of materials, the different containers being sorted by type of material; a weighing device for weighing each container; a dispenser for dispensing the particles of each type of material from each of the containers simultaneously into a mixing container; and wherein the dispensing of the particles from the respective container is stopped when the weight of the respective container reaches a predetermined weight.

40. the insulating particles include a mixture of particles from two or more types of materials, and the system comprises: different containers for receiving the particles of the two or more types of materials, the different containers being sorted by type of material; a dispenser for dispensing the particles of each type of material from the respective container into a mixing container; a metering device for metering the mixing vessel; 39. The system of any one of claims 34 to 38, comprising: a mixing vessel having a mixing chamber and a mixing chamber configured to mix particles together;

41. 41. The system of claim 39 or 40, wherein the particles in the mixing vessel are homogeneously mixed and transferred to two or more reservoirs, each reservoir being considered as one batch of the mixed particles, and the mixed particles are transferred in batches to fill a plurality of the bags.

42. a feeder for feeding two or more layers of film and / or fabric; a pressure and heating device for applying pressure and heat to two or more layers of the film and / or fabric to form the film material; a perforation punch for perforating the film material to form the perforations; The system of any one of claims 34 to 41, comprising:

43. a feeder for feeding the film material to form the bag; the one or more sealers are configured to seal the film material to form the one or more sealed sides of the bag but leave one side of the bag unsealed; the filler is configured to fill the insulating particles through the unsealed side of the bag; 43. The system of any one of claims 34 to 42, wherein one of the one or more sealers is configured to seal the unsealed side of the bag after the filling of the bag with the insulating particles is completed.

44. a plurality of plates for receiving one or more of the bags between two plates of the plurality of plates, the distance between the plates being adjustable to apply or release pressure to the bags to degas the bags; a heating element for heating the plate to provide a heat treatment to the bag when pressure is applied to the bag; The system of any one of claims 34 to 43, comprising:

45. 45. The system of claim 44, comprising a cooler for cooling the plate and cooling the bag when pressure is applied to the bag.

46. 46. ​​The system of any one of claims 34 to 45, comprising a double belt press conveyor comprising a first endless belt and a second endless belt, wherein the bag is positioned between the first endless belt and the second endless belt and transported along the length of both the first endless belt and the second endless belt through synchronous movement of the first endless belt and the second endless belt, and wherein the distance between the first endless belt and the second endless belt is adjustable to apply or release pressure to the bag.

47. 47. The system of claim 46, wherein a first piece of fabric is present between the first endless belt and the bag, and a second piece of fabric is present between the second endless belt and the bag, and the first piece of fabric and / or the second piece of fabric imprint a pattern on the bag when pressure is applied to the bag by the first endless belt and the second endless belt, respectively.

48. 47. The system of claim 46, wherein a surface of the first endless belt that contacts the bag is coated and a surface of the second endless belt that contacts the bag is coated, and one or both of the coated surfaces imprint a pattern on the bag when pressure is applied to the bag by the first endless belt and the second endless belt, respectively.

49. 49. The system of any one of claims 46 to 48, comprising one or more heaters for heating the first endless belt and / or the second endless belt to provide a heat treatment to the bag when pressure is applied to the bag by the first endless belt and the second endless belt.

50. two or more of the heaters arranged along the first endless belt and the second endless belt for gradually increasing the temperature of the first endless belt and / or the second endless belt in a direction in which the bag is transported by the first endless belt and / or the second endless belt, thereby heating the bag while maintaining pressure on the bag; a heating and compression module for applying a predetermined maximum pressure to the bag when the temperature rises near or is at a predetermined maximum temperature; 50. The system of claim 49, comprising:

51. 51. The system of claim 49 or 50, comprising one or more coolers for cooling the first endless belt and / or the second endless belt to cool the bag when pressure is applied to the bag by the first endless belt and the second endless belt.

52. 52. The system of claim 51, comprising two or more of the coolers arranged along the first and second endless belts to gradually reduce the temperature of the first and / or second endless belts to a predetermined cooling temperature in a direction in which the bag is transported by the first and / or second endless belts, thereby cooling the bag while maintaining pressure on the bag.

53. cleaning the bag after the insulating particles are sealed within the bag and before compressing the bag to remove any gas entrapped therein; cleaning the bag after it has cooled; 53. A system according to claim 51 or 52, comprising a cleaning device for carrying out the steps of:

54. 54. The system of any one of claims 34 to 53, comprising a tape and / or adhesive applicator for applying tape and / or adhesive to the bag to enable the bag to be adhered to another object, wherein a release liner is provided over the applied tape and / or adhesive.

55. a first pick and place device for stacking two or more of the bags on a bottom plate and stacking a top plate on top of the topmost stacked bag; a strapping device for strapping a bundle including the bottom plate, the top plate, and the bags stacked between the bottom plate and the top plate; 55. The system of any one of claims 34 to 54, comprising:

56. a platform for supporting the first frame layer; a second pick and place device, moving the bag and adhering the bag onto the first frame layer; moving a second frame layer and adhering the second frame layer onto the bag to form a framed bag including the first frame layer and the second frame layer as a frame structure; a second pick and place device for performing 56. The system of any one of claims 34 to 55, comprising:

57. 56. The system of any one of claims 34 to 55, comprising a third pick and place device for moving a single piece frame structure and adhering the single piece frame structure to the bag to form a framed bag.

58. inserting a first layer of a flame retardant device into a first opening of the frame structure to cover an exposed surface of the bag; inserting a second layer of a flame retardant device into a second opening in the frame structure to cover another exposed surface of the bag; 58. The system of claim 56 or 57, comprising a fourth pick and place device for performing

59. sealing a first exterior side of the framed bag; sealing a second outer side of the framed bag; 59. The system of any one of claims 56 to 58, comprising a seal applicator for performing the steps of: a) applying a seal to a seal applicator; and b) applying a seal to a seal applicator for applying the steps of: a) applying a seal to a seal applicator; and c) applying a seal to a seal applicator for applying the steps of: a) applying a seal to a seal applicator; and d ...

60. 60. A system according to any one of claims 34 to 59, comprising a vacuum suction device for drawing air from the bag using vacuum suction to degas the bag.

61. 61. A system as claimed in any one of claims 34 to 60, comprising a weighing device for weighing the bags after they have been sealed and filled, and if the weight of the bags is close to or exceeds the limits of an acceptable weight range, a feedback data signal for adjusting the powder dosage is electronically communicated to increase or decrease the dosage of the insulating particles filled into each bag.

62. The system of any one of claims 34 to 61, further comprising a vibration device for vibrating the bag to level the insulating particles packed in the bag during or before compressing the bag to remove gas contained in the bag.

63. an upper conveyor comprising a plurality of upper conveyor plates; a lower conveyor having a plurality of lower conveyor plates; Equipped with a framed or frameless version of the bag is positioned between an upper conveyor plate of the plurality of upper conveyor plates and a lower conveyor plate of the plurality of lower conveyor plates; 63. The system of any one of claims 34 to 62, wherein the upper conveyor plate is configured to apply pressure to the bag between the upper conveyor plate and the lower conveyor plate to degas the framed or frameless bag.

64. 64. The system of claim 63, wherein the upper conveyor plate or the lower conveyor plate comprises one or more biasing members to facilitate the release of pressure acting on the framed or frameless bag.

65. 65. The system of claim 63 or 64, wherein the upper or lower conveyor plate comprises a pushing mechanism comprising one or more cams attached to the upper or lower conveyor plate and a plurality of guides for applying pressure to the one or more cams to press the upper or lower conveyor plate against the bag, thereby applying pressure to the bag between the upper and lower conveyor plates.

66. 66. The system of any one of claims 63 to 65, wherein the upper or lower conveyor plate includes perforations for contacting and degassing the bag, and the perforations are in fluid connection with a vacuum suction device operable to draw air through the perforations.

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