Nonwoven mat

Abstract

The present invention relates to a nonwoven mat for heat insulation and fire protection, a method for manufacturing the nonwoven mat, a partition member, a battery housing and a battery pack, and the use of the nonwoven mat, battery spacer and battery housing for heat insulation and fire protection.

Description

[Technical Field]

[0001] The present invention relates to the fields of insulation and fire protection. More specifically, the present invention relates to nonwoven mats for thermal insulation and fire protection, methods for manufacturing the nonwoven mats, partition members, battery housings, and the use of the nonwoven mats, partition members, and battery housings. [Background technology]

[0002] Rechargeable energy storage systems, such as lithium-ion batteries, which comprise multiple battery cells, are well-known and used in various applications, including electric and hybrid vehicles. Rechargeable battery cells can overheat internally, potentially leading to an uncontrolled self-heating state that can result in a "thermal runaway" event. In lithium-ion batteries, thermal runaway can reach temperatures of over 1300°C and may involve the ejection of gas, metal fragments, or particles. Consequently, while these events are occurring, it is necessary to block or reduce heat transfer from the malfunctioning cell to other parts of the energy storage system to avoid or mitigate damage.

[0003] Inorganic materials, such as artificial inorganic materials, possess good thermal properties and are useful in several applications requiring high-temperature resistance, making them common materials in insulating material compositions. Therefore, one solution that can block or reduce heat transfer from thermal runaway events originating from overheated battery cells is to add an insulating barrier containing artificial inorganic materials between the battery cells. However, the specifications required for these insulating barriers to function in batteries are stringent, and in many cases even state-of-the-art barriers do not meet the necessary mechanical requirements.

[0004] Therefore, there is a clear need for novel materials and barriers that possess high quality, high performance, high strength, and high durability, and are suitable for thermal insulation and fire protection. [Overview of the project]

[0005] The inventors of this invention have developed a nonwoven mat for heat insulation and fire prevention, a method for manufacturing the nonwoven mat, a partition member, a battery housing, and a battery pack.

[0006] In particular, the nonwoven mat of the present invention has been observed to possess remarkably improved structural integrity and mechanical properties compared to previously disclosed thermal insulation mats. The mechanical properties of the nonwoven mat of the present invention, such as its deformation behavior under pressure, make it particularly suitable for thermal insulation and fire protection in battery-related applications.

[0007] The method of the present invention makes it possible to obtain a nonwoven mat with adjustable mechanical properties. Furthermore, because the method for manufacturing the nonwoven mat of the present invention is simple and inexpensive, it can be applied to the mass production of nonwoven mats.

[0008] Therefore, the first aspect of the present invention is i) - Multiple artificial inorganic fibers having hydroxyl groups (OH) on their surface and an average diameter of 6 microns or more, - Polymer binder, - Solvent and, A step of preparing a dispersion containing the following: ii) A step of forming the dispersed material into a web-like structure to obtain a nonwoven surface, iii) A step of drying the nonwoven surface from step (ii) while suctioning until the weight of the solvent on the nonwoven surface is less than 40% by weight of the total weight of the nonwoven surface. iv) A step of impregnating the nonwoven surface of step (iii) with a mixture containing at least one binder while suctioning, in order to obtain a permeated nonwoven surface, and v) A step of heating the permeable nonwoven surface obtained in step (iv) at a temperature of 30 to 300°C to obtain a nonwoven mat. The present invention relates to a nonwoven mat for thermal insulation and fire protection obtained by a method comprising the following:

[0009] In a second embodiment, the present invention is i) - Multiple artificial inorganic fibers having hydroxyl groups (OH) on their surface and an average diameter of 6 microns or more, - Polymer binder, - Solvent and, A step of preparing a dispersion containing the following: ii) A step of forming the dispersed material into a web-like structure to obtain a nonwoven surface, iii) A step of drying the nonwoven surface from step (ii) while suctioning until the weight of the solvent on the nonwoven surface is less than 40% by weight of the total weight of the nonwoven surface. iv) A step of impregnating the nonwoven surface of step (iii) with a mixture containing at least one binder while suctioning, in order to obtain a permeated nonwoven surface, and v) A step of heating the permeable nonwoven surface obtained in step (iv) at a temperature of 30 to 300°C to obtain a nonwoven mat. The present invention relates to a method for manufacturing a nonwoven mat for heat insulation and fire protection, which is equipped with the necessary components.

[0010] In a further embodiment, the present invention relates to a partition member configured to form a partition between (i) two battery cells, or (ii) a single battery cell and a member other than the single battery cell, comprising at least one nonwoven mat of the present invention as described in any particular embodiment.

[0011] In an additional embodiment, the present invention relates to a battery housing comprising a partition member and / or a nonwoven mat described in any of the particular embodiments of the present invention, comprising a partition member and / or a nonwoven mat described in any of the particular embodiments of the present invention, for housing at least one battery cell, preferably a plurality of battery cells forming a pack of cells.

[0012] In other embodiments, the present invention is - Multiple batteries, - The partition member and / or battery housing of the present invention as described in any of the specific embodiments, This relates to a battery pack that includes the following features.

[0013] In another aspect, the present invention relates to the use of the non-woven mat, partition member or battery housing of the present invention for insulation, preferably for battery insulation, more preferably for insulation of an electric vehicle battery.

[0014] In yet another aspect, the present invention relates to the use of the non-woven mat, partition member or battery housing of the present invention for fire protection, preferably for protecting a battery from fire, more preferably for protecting an electric vehicle battery from fire.

Brief Description of the Drawings

[0015] [Figure 1] Results of the deformation rate (%) of various non-woven mats under pressure. [Figure 2] Photograph of a scanning electron microscope of a non-woven mat. [Figure 3] Results of the deformation rate (%) of non-woven mats containing various penetration binders under pressure. [Figure 4] Image of a non-woven surface formed in a web shape. [Figure 5] Image of a compression jig used in the test of the deformation rate (%) under pressure. [Figure 6] Image of a part of a battery housing including a non-woven mat. [[ID=​​​​​​​​​​​​​​​ - Polymer binder, - Solvent and, A step of preparing a dispersion containing the following: ii) A step of forming the dispersed material from step (i) into a web-like structure to obtain a nonwoven surface, iii) A step of drying the nonwoven surface from step (ii) while suctioning until the weight of the solvent on the nonwoven surface is less than 40% by weight of the total weight of the nonwoven surface. iv) A step of impregnating the nonwoven surface of step (iii) with a mixture containing at least one binder while suctioning, in order to obtain a permeated nonwoven surface, and v) A step of heating the permeable nonwoven surface obtained in step (iv) at a temperature of 30 to 300°C to obtain a nonwoven mat. The present invention relates to a nonwoven thermal insulation mat obtained by a method comprising the following:

[0019] i) - Multiple artificial inorganic fibers having hydroxyl groups (OH) on their surface and an average diameter of 6 microns or more, - Polymer binder, - Solvent and, A step of preparing a dispersion containing the following: ii) A step of forming the dispersed material from step (i) into a web-like structure to obtain a nonwoven surface, iii) A step of drying the nonwoven surface from step (ii) while suctioning until the weight of the solvent on the nonwoven surface is less than 40% by weight of the total weight of the nonwoven surface. iv) A step of impregnating the nonwoven surface of step (iii) with a mixture containing at least one binder while suctioning, in order to obtain a permeated nonwoven surface, and v) A step of heating the permeable nonwoven surface obtained in step (iv) at a temperature of 30 to 300°C.

[0020] Process (i) In a particular embodiment, the dispersion of step (i) is - Multiple artificial inorganic fibers having hydroxyl groups (OH) on their surface and an average diameter of 6 microns or more, - Polymer binder, - Solvent and, It consists of.

[0021] In other specific embodiments, the dispersion of step (i) is - a) Multiple artificial inorganic fibers having hydroxyl groups (OH) on their surface and an average diameter of 6 microns or more, b) Multiple artificial inorganic fibers that do not have hydroxyl groups (OH) on their surface. A mixture of, - Polymer binder, - Solvent and, It consists of.

[0022] In other specific embodiments, the dispersion of step (i) is - a) Multiple artificial inorganic fibers having hydroxyl groups (OH) on their surface, and b) Multiple artificial inorganic fibers that do not have hydroxyl groups (OH) on their surface, especially those that do not have hydroxyl groups (OH) on their surface. A mixture comprising a plurality of artificial inorganic fibers (a) and (b) having an average diameter of 6 microns or more, - Polymer binder, - Solvent and, It consists of.

[0023] In the context of this invention, the term "artificial inorganic fiber" refers to artificial fibers that do not exist in nature, such as artificial fibers made from inorganic materials, mainly ceramic oxides, non-oxide ceramics, or combinations thereof. Examples of "ceramic oxides" include, but are not limited to, alumina, alumina silica, alumina boria silica, aluminum silicate, aluminum borosilicate, aluminumlite, silica, zirconia, zirconia silica, titania, titania silica, rare earth oxides, or combinations thereof. Examples of "non-oxide ceramics" include, but are not limited to, silicon carbide, silicon carbonitride, silicon oxycarbide, titanium silicon oxycarbide, silicon nitride, aluminum nitride, titanium silicon, alumina silicon nitride, or combinations thereof.

[0024] In certain embodiments, the artificial inorganic fibers of the nonwoven mat are artificial inorganic mineral fibers. In the context of this invention, the term "mineral" refers to fibers that are nonmetallic inorganic fibers.

[0025] In certain embodiments, the artificial inorganic fibers of the nonwoven mat are selected from commercially available artificial inorganic fibers. Commercially available artificial inorganic fibers include glass fibers, quartz fibers, aluminum borosilicate fibers, aluminum silicate, silica fibers, non-oxide fibers (e.g., silicon carbide, silicon carbonitride, silicon oxycarbide, titanium silicon oxycarbide), and these artificial inorganic oxide fibers sold by 3M (St. Paul, Minnesota) under the trade name "Nextel" (e.g., "Nextel 312", "Nextel 440", "Nextel 550", "Nextel 610", "Nextel 650", and "Nextel 720"), these artificial inorganic oxide fibers sold by Berkem GmbH (Freiberg, Germany) under the trade name "Berkotex®", and "Nicalon fibers" (e.g., "Nicalon", "HighNicalon", and "HighNicalon") sold by COI Ceramics. Examples include, but are not limited to, these artificial inorganic oxide fibers sold under the "Type S" brand, these artificial inorganic oxide fibers sold by Ube Industries under the trade name "Tyranno Fiber," or these artificial inorganic oxide fibers sold by Hitco Carbon Composites, Inc. (Gardena, California) under the trade name "Refraseal."

[0026] In certain embodiments, the artificial inorganic fiber is selected from fibers that sufficiently contain alumina (Al2O3), aluminalite, alumina silica, aluminum borosilicate, aluminum silicate, silica (SiO2), or mixtures thereof.

[0027] In a particular embodiment, the artificial inorganic fiber is selected from alumina-silica fibers, aluminum silicate fibers, silica (SiO2) fibers, or mixtures thereof.

[0028] In one embodiment, the artificial inorganic fiber having hydroxyl groups (OH) on its surface has a composition containing Si, preferably a composition containing Al and Si, more preferably a composition containing SiO2 and Al2O3. In a particular embodiment, the artificial inorganic fiber has hydroxyl groups (OH) on its surface and contains silicon atoms in its composition, with the hydroxyl groups covalently bonded to the silicon atoms of the fiber.

[0029] In certain embodiments, the artificial inorganic fiber has a composition containing more than 50% by weight of SiO2, preferably more than 60% by weight of SiO2, more preferably 70 to 99% by weight of SiO2, and more preferably a composition further containing 1 to 20% by weight of Al2O3.

[0030] Furthermore, in certain embodiments, artificial inorganic fibers are, - 80-99% by weight of SiO2, - 1-20% by weight of Al2O3, and - One or more components selected from Na2O, K2O, CaO, MgO, B2O3, TiO2, Fe oxide, ZrO2, BaO, PbO, ZnO, Cr2O3, and F. It has a composition that includes the following:

[0031] Furthermore, in certain embodiments, artificial inorganic fibers are substantially - 80-99% by weight of SiO2, - 1-20% by weight of Al2O3, and - One or more components selected from Na2O, K2O, CaO, MgO, B2O3, TiO2, Fe oxide, ZrO2, BaO, PbO, ZnO, Cr2O3, and F. It has a composition consisting of [the following].

[0032] In artificial inorganic fibers having hydroxyl groups on their surface, the hydroxyl groups are covalently bonded to the surface of the artificial inorganic fiber, preferably to the Si atoms of the artificial inorganic fiber. Furthermore, in a specific embodiment, the artificial inorganic fiber having hydroxyl groups on its surface has a composition containing Si atoms, with 20% or more Si atoms covalently bonded to the hydroxyl groups, preferably 25% or more Si atoms covalently bonded to the hydroxyl groups, more preferably 30-50% Si atoms covalently bonded to the hydroxyl groups, and even more preferably about 40% Si atoms covalently bonded to the hydroxyl groups.

[0033] Furthermore, in certain embodiments, artificial inorganic fibers having hydroxyl groups (OH) on their surface are obtained by a method comprising the step of extracting these fibers with acid, and preferably have a composition containing 70-99% by weight of SiO2. - 80-99% by weight of SiO2, - 1-20% by weight of Al2O3, It is more preferable to have a composition that includes one or more components selected from Na2O, K2O, CaO, MgO, B2O3, TiO2, Fe oxide, ZrO2, BaO, PbO, ZnO, Cr2O3, and F.

[0034] In certain embodiments, artificial inorganic fibers are (i) - 85~99% by weight of SiO2, - 1-5% by weight of Al2O3, - One or more components selected from Na2O, K2O, CaO, MgO, B2O3, TiO2, Fe oxide, ZrO2, BaO, PbO, ZnO, Cr2O3, and F, Compositions including, and / or (ii) - 80-95% by weight of SiO2, - 5-20% by weight of Al2O3, - One or more components selected from Na2O, K2O, CaO, MgO, B2O3, TiO2, Fe oxide, ZrO2, BaO, PbO, ZnO, Cr2O3, and F, It has a composition that includes the following:

[0035] Furthermore, in certain embodiments, artificial inorganic fibers are, - 90-98% by weight of SiO2, - 2-5 wt% Al2O3, The composition comprises one or more components selected from Na2O, K2O, CaO, MgO, B2O3, TiO2, Fe oxide, ZrO2, BaO, PbO, ZnO, Cr2O3, and F, and it is preferable that the composition comprises 0 to 3% by weight of Na2O and / or K2O and one or more components selected from CaO, MgO, B2O3, TiO2, Fe oxide, ZrO2, BaO, PbO, ZnO, Cr2O3, and F.

[0036] Furthermore, in certain embodiments, artificial inorganic fibers are, - 81-94% by weight of SiO2, - 6-19 wt% Al2O3, - One or more components selected from Na2O, K2O, CaO, MgO, B2O3, TiO2, Fe oxide, ZrO2, BaO, PbO, ZnO, Cr2O3 and F, preferably 2 to 12% by weight of ZrO2 and one or more components selected from Na2O, K2O, CaO, MgO, B2O3, TiO2, Fe oxide, BaO, PbO, ZnO, Cr2O3 and F, It has a composition that includes the following:

[0037] Furthermore, in certain embodiments, the artificial inorganic fiber contains Al and Si in a molar ratio of Al:Si of approximately 1:18.

[0038] In the context of this invention, the term "weight" means a weight percentage of the total weight of the product or composition, as is well known in the art.

[0039] In one embodiment, the artificial inorganic fiber of step (i) has an average diameter of 7 microns or more, preferably 8 microns or more, more preferably 9 microns or more, and even more preferably 10 microns or more.

[0040] In one embodiment, the artificial inorganic fiber of step (i) has an average diameter of 6 to 50 microns, preferably 7 to 40 microns, more preferably 7.5 to 30 microns, and even more preferably about 11 microns.

[0041] In the context of this invention, the expression "average diameter" with respect to a fiber is synonymous with the "average thickness" of the fiber, and is a parameter measured as the arithmetic mean of the diameters of representative samples of multiple artificial inorganic fibers, and furthermore, this parameter is measured by means known in the art, such as a scanning microscope. In the context of this invention, the expression "fiber diameter" or "multiple fiber diameters" refers to the shorter dimension of the fiber. In the context of this invention, the expression "fiber length" or "multiple fiber lengths" refers to the longer dimension of the fiber.

[0042] In a particular embodiment, the artificial inorganic fiber in step (i) is a short fiber. In certain embodiments, the artificial inorganic fibers of step (i) are dispersed. In the context of the present invention, the term "dispersed" is the opposite of aggregated or clumped. Suitable artificial inorganic fibers for the present invention include, but are not limited to, straight fibers, crimped fibers, or roving fibers.

[0043] In certain embodiments, the dispersion of step (i) further contains hydroxyl group (OH)-free artificial inorganic fibers, such as annealed artificial inorganic fibers, and in particular, artificial inorganic fibers that do not have hydroxyl group (OH) on their surface. The hydroxyl group (OH)-free artificial inorganic fibers may possess all the properties specified above for any embodiment of the artificial inorganic fibers of step (i).

[0044] In the context of the present invention, artificial inorganic fibers that do not have hydroxyl groups (OH), in particular artificial inorganic fibers that do not have hydroxyl groups (OH) on their surface, are understood to be fibers containing Si atoms, wherein less than 15%, preferably less than 10%, more preferably less than 5%, even more preferably less than 3%, less than 2%, or less than 1% of Si atoms are covalently bonded to the hydroxyl groups.

[0045] In a further specific embodiment, the amount of artificial inorganic fibers having hydroxyl groups (OH) on their surface in the dispersion of step (i) is less than 60% by weight, preferably less than 50% by weight, more preferably less than 40% by weight, and even more preferably less than 30% by weight, relative to the total weight of the artificial inorganic fibers in the dispersion of step (i).

[0046] In a further specific embodiment, the amount of artificial inorganic fibers having hydroxyl groups (OH) on their surface in the dispersion of step (i) is 10 to 60% by weight, preferably 15 to 50% by weight, more preferably 20 to 40% by weight, and even more preferably 25 to 30% by weight, relative to the total weight of the artificial inorganic fibers in the dispersion of step (i).

[0047] The inventors of this invention believe that by using artificial inorganic fibers having hydroxyl groups (OH) on their surface, particularly when the average diameter is 6 microns or more, and especially when the average diameter is about 11 microns, in the dispersion in step (i), the drying of the nonwoven surface in step (ii) is improved. As a result, the interaction between the fibers and the penetrating binder in the nonwoven mat under suction improves the durability, high temperature resistance, and fire resistance of the nonwoven mat of this invention, resulting in superior mechanical properties compared to those described in this art. Furthermore, the inventors of this invention have observed that using artificial inorganic fibers with an average diameter of 6 microns or more results in a product that is easy to handle and assemble, possesses high porosity, and has high flexibility.

[0048] Furthermore, the inventors of the present invention observed that when the nonwoven mat contains a mixture of artificial inorganic fibers having hydroxyl groups (OH) on its surface and artificial inorganic fibers not having hydroxyl groups (OH) on its surface, the amount of defects decreases. In addition, the inventors observed that when the nonwoven mat contains a mixture of artificial inorganic fibers partially having hydroxyl groups (OH) on its surface and partially not having hydroxyl groups (OH) on its surface, the shrinkage of the nonwoven mat during high-temperature processing decreases, and the quality improves.

[0049] In the context of the present invention, the term “binder” refers to a substance that helps artificial inorganic fibers stick together by adhesion or aggregation. In the context of the present invention, the expression “polymeric binder” refers to the binder in the dispersion of step (i), and the expression “at least one binder” refers to one or more binders added to the mixture or nonwoven mat of step (iv).

[0050] In certain embodiments, the polymer binder is a polymer selected from thermoplastic polymers, polyacrylates, polyurethanes, epoxy resins, phenolic resins, thermosetting resins, photosensitive resins, polyester resins, or mixtures thereof.

[0051] In certain embodiments, the polymer binder is poly(methyl methacrylate) (PMMA), polycarbonate (PC), polystyrene (PS), polypropylene (PP), polyethylene (PE), polyglycolide (PGA), poly(propylene fumarate) (PPF), polycyanoacrylate (PCA), polycaprolactone (PCL), poly(glycerol sebacate) (PGS), poly(glycerol acrylate sebacate) (PGSA), polyvinylidene fluoride (PVDF), polyvinylidene chloride (PVDC), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyphenylene oxide (PPO), polyvinyl chloride (PVC), cellulose acetate (CA), cyclic olefin copolymer (COC), ethylene vinyl acetate (EVA), ethylene vinyl alcohol (EVOH), polytetrafluoroethylene (PT) Selected from FE), fluorinated ethylene propylene (FEP), perfluoroalkoxy (PEA), ethylene tetrafluoroethylene (ETFE), polyethersulfone (PES), chlorinated polyethylene (CPE), polylactic acid (PLA), poly(3-hydroxybutyrate) (P3HB), butylene polyadipate (PBA), ethylene polyadipate (PEA), polybutylene succinate (PBS), polyphenylene sulfide (PPS), polysulfone (PSU), polytrimethylene terephthalate (PTT), polyurethane (PU), polyvinyl acetate, polyvinylidene chloride (PVDC), styrene acrylonitrile (SAN), polyether ketone (PEEK), polyvinyl alcohol (PVA), polyhydroxyethyl methacrylate (PHEMA), poly(N-isopropylacrylamide) (PNIPAAm), and mixtures thereof.

[0052] In certain embodiments, the polymer binder is poly(methyl methacrylate) (PMMA), polycarbonate (PC), polystyrene (PS), polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyphenylene oxide (PPO), polyvinyl chloride (PVC), cellulose acetate (CA), cyclic olefin copolymer (COC), ethylene vinyl acetate (EVA), ethylene vinyl alcohol (EVOH), polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), perfluoroalkoxy (PEA), ethylene tetrafluoroethylene (ETFE), polyethersulfone ( Selected from PES, chlorinated polyethylene (CPE), polylactic acid (PLA), poly(3-hydroxybutyrate) (P3HB), butylene polyadipate (PBA), ethylene polyadipate (PEA), polybutylene succinate (PBS), polyphenylene sulfide (PPS), polysulfone (PSU), polytrimethylene terephthalate (PTT), polyurethane (PU), polyvinyl acetate, polyvinylidene chloride (PVDC), styrene acrylonitrile (SAN), polyether ketone (PEEK), polyvinyl alcohol (PVA), polyhydroxyethyl methacrylate (PHEMA), poly(N-isopropylacrylamide) (PNIPAAm), and mixtures thereof.

[0053] In certain embodiments, the polymeric binder is a vinyl polymer selected from polyvinyl chloride (PVC), polyvinyl acetate, polyvinyl alcohol (PVA), and mixtures thereof, preferably polyvinyl alcohol (PVA).

[0054] In certain embodiments, the polymer binder in the dispersion of step (i) is 1 to 20% by weight of the total weight of the dispersion, preferably 2 to 15% by weight, more preferably 4 to 10% by weight, and even more preferably about 6% by weight.

[0055] In certain embodiments, the polymer binder is polymer fibers. In other embodiments, the polymer binder in step (i) is not polymer fibers.

[0056] The inventors of the present invention have observed that a method comprising a first step of preparing a dispersion containing artificial inorganic fibers having hydroxyl groups (OH) on their surface and an average diameter of 6 microns or more, a polymer binder, and a solvent can provide a uniform nonwoven mat with fewer defects compared to using fibers with an average diameter of less than 6 microns.

[0057] In the context of the present invention, the term "dispersed material" refers to a mixture or slurry of at least one solid element, such as artificial inorganic fibers, dispersed in a solvent such as water.

[0058] Suitable solvents for the present invention include, but are not limited to, methanol, 2-propanol, chloroform, toluene, anisole, cyclohexane, dimethylformamide, methanol, dichloromethane, trichloroethane, water, acetone, ethyl acetate, N-methyl-2-pyrrolidone, and mixtures thereof. In certain embodiments, the dispersion of step (i) contains a solvent selected from methanol, ethanol, and water, and preferably contains water.

[0059] In certain embodiments, the dispersion of step (i) is stable. The dispersion prepared in step (i) can be prepared by dispersing the artificial inorganic fibers and polymer binder, and optionally other additives, in a suitable solvent by applying energy using mechanical methods known in the art, such as dispersers, agitators, or ultrasonic baths and / or probes. Other alternative methods known in the art for preparing a stable dispersion suitable for the present invention include adding additives (surfactants) to the dispersion to control surface tension, or modifying the surface of the artificial inorganic fibers with bound or unbound ligand molecules. The quality of the dispersion can be evaluated by its stability, specifically whether it aggregates or precipitates over a period of time. In particular, the artificial inorganic fibers should not aggregate or clump during the manufacturing process, i.e., from a few minutes to several hours. Turbidimetric methods or turbidimetric analysis and / or dynamic light scattering can be used to monitor the stability of the dispersion.

[0060] The inventors of the present invention have observed that using a polymer binder in the dispersion improves the stability of the dispersion, i.e., reduces the precipitation and / or aggregation of artificial inorganic fibers.

[0061] In one embodiment, the dispersion further contains one or more additives. In one embodiment, one or more additives are selected from thickeners, surfactants and / or artificial inorganic precursors.

[0062] In certain embodiments, the dispersion of step (i) or the mixture of step (iv) further contains at least one aerogel, preferably a hydrophobic aerogel.

[0063] In a further specific embodiment, the dispersion of step (i) or the mixture of step (iv) further contains a silica aerogel, preferably an amorphous silica aerogel, and more preferably a hydrophobic amorphous silica aerogel.

[0064] In the context of this invention, the term "hydrophobic" is understood to be publicly known in the art.

[0065] In certain embodiments, the aerogel is in the form of particles or granules.

[0066] In certain embodiments, the average particle size of the aerogel is 0.01 to 7 millimeters, preferably 0.04 to 5 millimeters, more preferably 0.10 to 4 millimeters, and even more preferably 1 to 3 millimeters.

[0067] In another specific embodiment, the average particle size of the aerogel is 0.1 to 200 micrometers, more preferably 0.5 to 150 micrometers, and even more preferably 0.2 to 100 micrometers.

[0068] In the context of the present invention, the expression "average particle size" with respect to aerogel refers to a parameter measured as the arithmetic mean of the diameters of representative samples of multiple aerogel particles or aerogel granules, and furthermore, this parameter is measured by means known in the art, such as scanning microscopy.

[0069] As used in this invention, the term "aerogel" refers to a low-density porous material, which is generally solid, and is obtained by removing the liquid from a gel by replacing the liquid with gas or vacuum without shrinking the shape of the liquid-containing gel, and is generally obtained by sol-gel manufacturing methods known in the art. In particular, the density of aerogels is typically about 50-200 kg / m³ 3 That is the case.

[0070] Silica aerogels are, but are not limited to, silica aerogels that can be used in this invention. Silica aerogels are widely known and commercially available in the field of this invention. Any silica aerogel recognized in this field is expected to be usable in connection with this invention. Examples of silica aerogels include, but are not limited to, those of Cabot, Geos Aerogels, or Svenska Aerogels. Methods for producing these aerogels are also widely known in this field. Generally, gels are produced by forming a three-dimensional microstructure. For example, a gel can be produced by agglomerating colloidal silica particles under, for example, acidic conditions to form a three-dimensional gel microstructure. Aerogels are formed when the gel is dried or when the liquid is removed from the pores of the gel. The fluid can be removed by any method that is appropriate for substantially preserving the microstructure of the gel. For example, methods for removing the fluid may include supercritical fluid extraction, liquid evaporation, or freeze-drying. The gel can then be formed into particles until the final desired aerogel particle size is obtained.

[0071] In certain embodiments, the dispersion of step (i) further contains at least one thickener, preferably a polymeric thickener. In the context of the present invention, the term “thickener” refers to a compound that increases the density of the dispersion of step (i). Suitable thickeners for the present invention include colloidal silica, colloidal alumina, sodium alginate (E-401), potassium alginate (E-402), ammonium alginate (E-403), calcium alginate (E-404), and mixtures thereof.

[0072] In certain embodiments, the dispersion of step (i) further contains at least one surfactant. Suitable surfactants include anionic surfactants, cationic surfactants, nonionic surfactants, amphoteric surfactants, or combinations thereof. Examples of anionic surfactants include carboxylic acid-type surfactants, sulfate-type surfactants, sulfonic acid-type surfactants, and phosphate-type surfactants. Examples of cationic surfactants include amine salt-type surfactants, primary amine salt-type surfactants, secondary amine salt-type surfactants, tertiary amine salt-type surfactants, and quaternary amine salt-type surfactants. Examples of nonionic surfactants include ester-type surfactants, ester ether-type surfactants, and ether-type surfactants. Examples of amphoteric surfactants include amino acid-type surfactants and sulfobetaine-type surfactants.

[0073] The inventors of this invention observed that the use of additives improves the dispersibility of fibers in nonwoven mats, without being particularly bound by any theory. The inventors of this invention also observed that the use of polymer binders improves the stability of nonwoven mats, without being particularly bound by any theory.

[0074] Process (ii)

[0075] In the present invention, a nonwoven mat is obtained by the above method, which includes the step (ii) of forming a dispersion into a web-like structure to obtain a nonwoven surface. In the context of the present invention, the expression "forming into a web-like structure" refers to an operation known in the art to form a nonwoven surface containing fibers, and specific types of forming into a web-like structure include, for example, wet lamination and melt spinning. In a particular embodiment, the step of forming into a web-like structure is performed using a long-screen paper machine known in the art.

[0076] In a particular embodiment, step (ii) of forming a web comprises a step of wet lamination of the dispersion from step (i) to obtain a nonwoven surface. In another particular embodiment, step (ii) of forming a web consists of a step of wet lamination of the dispersion from step (i) to obtain a nonwoven surface. In the context of the present invention, the expression "wet lamination" refers to an operation known in the art, in which a dispersion containing at least fibers and a solvent, such as the dispersion described in step (i) of the method of the present invention, is passed on a moving belt, and the fibers form a nonwoven surface at that location.

[0077] Process (iii)

[0078] In a particular embodiment, the step of drying the nonwoven surface while suctioning in step (ii) is performed for 1 to 300 seconds, preferably 5 to 120 seconds, and more preferably 5 to 30 seconds.

[0079] In certain embodiments, the step of drying the nonwoven surface while suctioning is performed with a pressure difference of 1 mbar to 10 bar, preferably 2 mbar to 1 bar, and more preferably 5 mbar to 200 mbar.

[0080] In certain embodiments, the step of drying the nonwoven surface while suctioning refers to the process of suctioning and discharging a portion of the solvent from the nonwoven surface.

[0081] In the context of the present invention, the term "nonwoven surface" refers to a product, sheet, blanket, or layer containing physically intertwined artificial inorganic fibers, a polymer binder that assists the artificial inorganic fibers in bonding or agglomerating with each other, and a solvent.

[0082] In certain embodiments, the nonwoven surface obtained in step (iii) contains less than 40% by weight of the solvent, preferably less than 35% by weight, more preferably less than 30% by weight, and even more preferably less than 25% by weight, less than 20% by weight, or less than 15% by weight of the solvent, based on the total weight of the nonwoven surface.

[0083] The inventors of this invention, without being particularly bound by any theory, believe that when the nonwoven surface is dried while being suctioned and the solvent reaches less than 40% by weight of the total weight of the nonwoven surface, the interaction between the artificial inorganic fibers and the binder added in step (iv) is improved, and the mechanical properties of the nonwoven mat of this invention are improved.

[0084] Process (iv)

[0085] In a particular embodiment, the step of obtaining a permeable nonwoven surface by impregnating the nonwoven surface of step (iii) with a mixture containing at least one binder while suctioning is performed for 0.01 to 30 seconds, preferably 0.1 to 15 seconds, and more preferably 0.5 to 10 seconds.

[0086] In a particular embodiment, the step of obtaining a permeable nonwoven surface by impregnating the nonwoven surface of step (iii) with a mixture containing at least one binder while suctioning is carried out with a pressure difference of 1 mbar to 10 bar, preferably 2 mbar to 1 bar, and more preferably 5 mbar to 200 mbar.

[0087] In a particular embodiment, the step of obtaining a permeable nonwoven surface by impregnating the nonwoven surface of step (iii) with a mixture containing at least one binder while suctioning is performed at a suction rate of 20 to 80% of the total suction rate.

[0088] In one embodiment, the binder in the mixture of step (iv) is an inorganic binder. In a particular embodiment, the binder in the mixture of step (iv) is selected from silica, alumina, aluminum phosphate, sodium silicate, or a mixture thereof, preferably colloidal silica or colloidal alumina, and more preferably colloidal silica.

[0089] In one embodiment, the binder in the mixture of step (iv) is an organic binder. In a more specific embodiment, the organic binder contains silicone, polyvinyl alcohol, ethylene, vinyl acetate, or a mixture thereof, preferably ethylene, vinyl acetate, or a mixture thereof.

[0090] In one embodiment, the binder in the mixture of step (iv) is a silicone, preferably a hydrophilic silicone.

[0091] In one embodiment, the mixture of step (iv) contains an organic binder and an inorganic binder.

[0092] In a further specific embodiment, the organic binder is a dispersion containing ethylene, vinyl acetate, or a mixture thereof. In one embodiment, the dispersion further contains a compound selected from acrylate, vinyl chloride, and / or formaldehyde.

[0093] In certain embodiments, the mixture of step (iv) further contains a solvent, preferably selected from methanol, ethanol, and water, more preferably water.

[0094] In one embodiment, the dispersion of step (i) or the mixture of step (iv) further contains one or more suitable flame retardants. In one embodiment, suitable flame retardants for the present invention include reactive flame retardants and additive flame retardants known in the art. The selection of flame retardants often depends on the service application of the planned formulation and, incidentally, on the flammability test scenarios known in the art that define that application. In further specific embodiments, the flame retardants in the present invention are selected from organic flame retardants such as organohalogen compounds, organophosphorus compounds, melamine or polyols, inorganic flame retardants such as aluminum hydroxide (ATH), magnesium hydroxide (MDH), huntite and dolomitic, or mixtures thereof. Examples of such flame retardants include, but are not limited to, chlorinated phosphate esters, chlorinated paraffins, melamine, ammonium polyphosphate, polyols, and mixtures thereof.

[0095] In a particular embodiment, the mixture in step (iv) is - An inorganic binder selected from silica, alumina, aluminum phosphate, sodium silicate, or a mixture thereof. - Organic binders containing polyvinyl alcohol, ethylene, vinyl acetate, or mixtures thereof. - Silicone, upon request - Flame retardant, and, upon request - water It contains.

[0096] In a particular embodiment, the mixture in step (iv) is - An inorganic binder selected from silica, alumina, aluminum phosphate, sodium silicate, or a mixture thereof. - Organic binders containing polyvinyl alcohol, ethylene, vinyl acetate, or mixtures thereof. - Silicone, upon request - Flame retardant, and, upon request - water It consists of.

[0097] The inventors of this invention believe that, without being particularly bound by any theory, by impregnating a nonwoven surface with a mixture containing at least one type of binder while suctioning, the binder is uniformly dispersed throughout the nonwoven surface, the interaction between the binder and the artificial inorganic fibers is improved, and the mechanical properties of the final nonwoven mat are improved.

[0098] Process (v)

[0099] According to the present invention, a nonwoven mat can be obtained by the above method, which includes step (v) of heating the permeable nonwoven surface obtained in step (iv) at a temperature of 30 to 300°C.

[0100] In a particular embodiment, the heating in step (v) is carried out under atmospheric pressure.

[0101] In certain embodiments, the heating in step (v) is carried out at a temperature of 50 to 250°C, preferably 100 to 200°C, and more preferably 120 to 180°C.

[0102] In a particular embodiment, the heating in step (v) is carried out for 5 seconds to 60 minutes, preferably 10 seconds to 40 minutes, and more preferably 15 seconds to 30 minutes.

[0103] In certain embodiments, heating in step (iii) is carried out by infrared irradiation. In certain embodiments, heating in step (iii) is carried out in a furnace, preferably an infrared furnace.

[0104] Nonwoven surface

[0105] In the context of this invention, the term "nonwoven surface" refers to a product, sheet, blanket, or layer containing multiple artificial inorganic fibers having hydroxyl groups (OH) on their surface, an average diameter of 6 microns or more, and being physically intertwined, along with a polymer binder and a solvent. The nonwoven surface is porous, with pores remaining due to the gaps between the artificial inorganic fibers. The term "nonwoven surface" is also referred to as a "nonwoven product," "nonwoven sheet," "nonwoven blanket," or "nonwoven layer." The term "surface" in relation to a nonwoven surface is understood to refer to a nonwoven product such as a nonwoven sheet, nonwoven blanket, or nonwoven layer having a certain thickness in the short direction, as is well known in the art.

[0106] In certain embodiments, the thickness of the nonwoven surface is 0.1 millimeters or more, preferably 0.5 millimeters or more, and more preferably 1 millimeter or more.

[0107] In certain embodiments, the thickness of the nonwoven surface is 0.1 to 10 millimeters, preferably 0.5 to 8 millimeters, and more preferably 1 to 5 millimeters.

[0108] Nonwoven mat

[0109] The nonwoven mat of the present invention - Multiple artificial inorganic fibers having hydroxyl groups (OH) on their surface and an average diameter of 6 microns or more, - Polymer binder, - At least one type of impregnation binder, It may contain [a certain substance], and if desired, the density of the nonwoven mat can be 20 to 1000 kg / m². 3 That is the case.

[0110] The inventors of this invention have observed that the dispersion of polymer binders and impregnation binders within the nonwoven mat, and the interaction between these binders and fibers, are results of different manufacturing processes for the nonwoven mat, and that these affect the final properties of the mat, such as mechanical properties and electrical conductivity.

[0111] In one embodiment, the nonwoven mat of the present invention is - Multiple artificial inorganic fibers having hydroxyl groups (OH) on their surface and an average diameter of 6 microns or more, - If desired, a plurality of artificial inorganic fibers that do not have hydroxyl groups (OH) on their surface, such as annealed artificial inorganic fibers, - Polymer binder, - At least one type of impregnation binder, It consists of [materials], and the density of the nonwoven mat can be 20-1000 kg / m³ as desired. 3 That is the case.

[0112] In another embodiment, the nonwoven mat of the present invention is - (a) Artificial inorganic fibers having hydroxyl groups (OH) on their surface, and (b) Multiple artificial inorganic fibers that do not have hydroxyl groups (OH) on their surface, such as annealed artificial inorganic fibers Multiple artificial inorganic fibers having an average diameter of 6 microns or more, - Polymer binder, - At least one type of impregnation binder, It consists of [materials], and the density of the nonwoven mat can be 20-1000 kg / m³ as desired. 3 That is the case.

[0113] In another embodiment, the nonwoven mat of the present invention is - (a) Artificial inorganic fibers having hydroxyl groups (OH) on their surface, and (b) Multiple artificial inorganic fibers that do not have hydroxyl groups (OH) on their surface, such as annealed artificial inorganic fibers Multiple artificial inorganic fibers having an average diameter of 6 microns or more, - Polymer binder, - At least one type of impregnation binder, - Flame retardant and, upon request - Silicone and, upon request It consists of [materials], and the density of the nonwoven mat can be 20-1000 kg / m³ as desired. 3 That is the case.

[0114] In certain embodiments, the nonwoven mat contains at least one binder of step (iv) or a derivative thereof, uniformly dispersed throughout the nonwoven mat, particularly over the total thickness of the nonwoven mat. In the context of the present invention, the expression "derivative of at least one binder of step (iv)" refers to a compound produced after heating at least one binder in step (v) at a temperature of 30 to 300°C. The artificial inorganic fibers, polymer binder, or at least one impregnating binder in the nonwoven mat of the present invention may each have all the properties described above of the artificial inorganic fibers of step (i), the polymer binder of step (i), or at least one binder of step (iv).

[0115] In certain embodiments, the porosity of the nonwoven mat is 50% or more, preferably 60% or more, more preferably 70% or more, and even more preferably 80% or more.

[0116] In the context of the present invention, the term "porosity" in relation to a nonwoven surface or nonwoven mat refers to the void ratio generated by pores or gaps between fibers. Porosity is understood as the ratio of the volume of voids to the total volume, expressed as a percentage between 1% and 100%. Accordingly, in the context of the present invention, one or more terms for "pores" refer to the gaps between artificial inorganic fibers in either a nonwoven surface or a nonwoven mat. The average diameter of the pores is preferably 1 to 100 microns, and more preferably 5 to 50 microns.

[0117] In a particular embodiment, the density of the nonwoven mat is 20 kg / m². 3 The above is preferable, preferably 30 kg / m 3as above, more preferably 50 kg / m 3 as above, even more preferably 60 kg / m 3 as above.

[0118] In certain embodiments, the density of the non-woven mat is 20 to 1000 kg / m 3 and preferably 30 to 900 kg / m 3 and more preferably 50 to 850 kg / m 3 and even more preferably 60 to 800 kg / m 3 and is.

[0119] In even more specific embodiments, the thickness of the non-woven mat obtained by the method described above is 0.05 to 20 mm, preferably 0.10 to 15 mm, more preferably 0.15 to 10 mm, and even more preferably 0.2 to 8 mm.

[0120] In even more specific embodiments, the non-woven mat obtained by the method described above contains at least one penetrating binder (e.g., one binder or a plurality of binders) throughout the non-woven mat, preferably throughout the total thickness of the non-woven mat. In certain embodiments, at least one penetrating binder is uniformly dispersed in the non-woven mat.

[0121] The inventors have observed that one or more penetrating binders are uniformly dispersed throughout the total thickness of the non-woven mat with improved mechanical properties and electrical conductivity.

[0122] Method

[0123] In other aspects, the present invention i) - a plurality of artificial inorganic fibers having hydroxyl groups (OH) on the surface and an average diameter of 6 microns or more, - a polymer binder, - a solvent, preparing a dispersion containing; ii) forming the dispersion of step (i) into a web to obtain a non-woven surface, iii) A step of drying the nonwoven surface from step (ii) while suctioning until the weight of the solvent on the nonwoven surface is less than 40% by weight. iv) A step of impregnating the nonwoven surface of step (iii) with a mixture containing at least one binder while suctioning, in order to obtain a permeated nonwoven surface, and v) A step of heating the permeable nonwoven surface obtained in step (iv) at a temperature of 30 to 300°C. The present invention relates to a method for manufacturing a nonwoven mat for heat insulation and fire protection, which is equipped with the necessary components.

[0124] In one embodiment, a method for manufacturing a nonwoven mat for heat insulation is as follows: i) - Multiple artificial inorganic fibers having hydroxyl groups (OH) on their surface and an average diameter of 6 microns or more, - Polymer binder, - Solvent and, A step of preparing a dispersion containing the following: ii) A step of forming the dispersed material into a web-like structure to obtain a nonwoven surface, iii) A step of drying the nonwoven surface from step (ii) while suctioning until the weight of the solvent on the nonwoven surface is less than 40% by weight. iv) A step of impregnating the nonwoven surface of step (iii) with a mixture containing at least one binder while suctioning, in order to obtain a permeated nonwoven surface, and v) A step of heating the permeable nonwoven surface obtained in step (iv) at a temperature of 30 to 300°C. It consists of.

[0125] The method described above, with respect to the steps of the method for nonwoven mats of the present invention as specified above, possesses all the advantages and features specified above in any embodiment.

[0126] Partition members, battery housings, and battery packs

[0127] In a further embodiment, the present invention relates to a partition member configured to form a partition between two battery cells, or between a single battery cell and a member other than a single battery cell, comprising at least one nonwoven mat of the present invention as described in any of the particular embodiments. In certain embodiments, the partition member consists of one or more nonwoven mats of the present invention as described in any of the particular embodiments, preferably consisting of one nonwoven mat of the present invention as described in any of the particular embodiments.

[0128] In an additional aspect, the present invention relates to a battery housing comprising a partition member of the present invention as described in any particular embodiment, comprising a partition member of the present invention for partitioning at least one cavity, preferably an opening, for housing, and preferably for housing, at least one battery cell, preferably a plurality of battery cells forming a pack of cells.

[0129] In an additional aspect, the present invention relates to a battery housing comprising a nonwoven mat of any embodiment disclosed herein, comprising partitioning at least one cavity, preferably an opening, for housing, preferably a plurality of battery cells, preferably forming a pack of cells.

[0130] In certain embodiments, the battery housing consists of at least one nonwoven mat from any of the embodiments disclosed to date, and in even more certain embodiments, the battery housing consists of one nonwoven mat from any of the embodiments disclosed to date.

[0131] In certain embodiments, the battery housing further comprises a partition member of the present invention as described in any of the particular embodiments.

[0132] In certain embodiments, the plurality of battery cells are provided with partition members that separate at least two cells from each other, or a single battery cell from a component other than a single battery cell, and the partition members are preferably partition members of the present invention as described in any of the particular embodiments.

[0133] In a preferred embodiment, the battery housing is made by combining one or more die-cut sheets, preferably consisting of one or more nonwoven mats according to any of the previously disclosed embodiments, and more preferably consisting of one nonwoven mat according to any of the previously disclosed embodiments. In a preferred embodiment, one or more curved die-cut sheets form the bottom surface and one or more side walls.

[0134] In other embodiments, the present invention is - Multiple batteries, - A battery housing of the present invention as described in any of the specific embodiments, This relates to a battery pack that includes the following features.

[0135] use

[0136] In another embodiment, the present invention relates to the use of a nonwoven mat, partition member or battery housing for thermal insulation, preferably for thermal insulation of a battery, and more preferably for thermal insulation of an electric vehicle battery.

[0137] In another embodiment, the present invention relates to a method for insulating an object, comprising the step of separating the object from other objects using the nonwoven mat, partition member or battery housing of the invention, wherein the object is preferably one or more batteries, and more preferably one or more batteries of an electric vehicle.

[0138] In another embodiment, the present invention relates to the use of a nonwoven mat, partition member or battery housing for fire prevention, preferably for protecting a battery from fire, and more preferably for protecting an electric vehicle battery from fire.

[0139] In another embodiment, the present invention relates to a method for protecting an object from fire, comprising the step of separating the object from other objects using the nonwoven mat, partition member or battery housing of the invention, wherein the object is preferably one or more batteries, and more preferably one or more batteries of an electric vehicle.

[0140] The nonwoven mat, partition member, battery housing, battery pack, method for manufacturing the nonwoven mat, and use of the nonwoven mat all possess all the advantages and features specified above for any embodiment of the nonwoven mat of the present invention. Throughout the specification and claims, the word “includes” and variations thereof are not intended to exclude other technical features, additives, components, or processes. Furthermore, the word “includes” encompasses the case of “consisting of.” Further objects, advantages, and features of the invention will become apparent to those skilled in the art by examining the specification or by the practice of the invention. The following examples are provided for illustrative purposes only and are not intended to limit the invention. Furthermore, the invention encompasses all possible combinations of the specific and preferred embodiments described herein. [Examples]

[0141] The invention will be explained by the following examples, but these examples are not intended to limit the scope of the invention. Example 1: Preparation of a nonwoven mat impregnated with colloidal silica

[0142] A nonwoven mat was prepared as follows, following an adapted technique (see Figure 4) for "web-like formation" based on technology used in papermaking using a long-wire paper machine. Artificial inorganic fibers with hydroxyl groups (OH) on their surface and an average diameter of 6 microns or more, obtained from Berkem under the trade name "Berkotex®," were used. The artificial inorganic fibers were dispersed in water by applying mechanical energy using a disperser in an open container. Polyvinyl alcohol (PVA) was also added to the dispersion as a polymer binder. Next, a nonwoven surface containing artificial inorganic fibers and PVA was continuously formed by forming the above dispersion into a web-like structure using a long-wire paper machine (i.e., depositing the dispersion on a continuously moving framed belt). Next, the nonwoven surface was dewatered by suction using a vacuum pump until the water content reached 25-20% by weight of the total weight of the nonwoven surface. A composition of colloidal silica (Rudox®) and water was impregnated into a nonwoven surface while suctioning to obtain a permeable nonwoven surface. Next, the permeable nonwoven surface was stabilized and dried while being heated in an infrared heating furnace at a temperature of 30 to 300°C until a density of 60 kg / m³ was obtained. 3 A nonwoven mat was obtained (see Figures 1(i) and 2). Based on the ASTM D3574 standard method known in this field, the deformation rate (%) of nonwoven mats under pressure was inspected using a Shimadzu (registered trademark) machine (see Figure 5). The results obtained for the nonwoven mats are shown in Figure 1(i). The applicants observed that using artificial inorganic fibers having hydroxyl groups (OH) on their surface and an average diameter of 6 microns or more reduces the amount of water on the nonwoven surface before binder impregnation. This, combined with the addition of the impregnation binder while suctioning, results in better mechanical and insulating properties of the final nonwoven mat compared to nonwoven mats obtained using other types of fibers. The inventors observed that this effect is particularly important when using artificial inorganic fibers having hydroxyl groups (OH) on their surface and an average diameter of approximately 11 microns. The process was the same as that described in the above embodiment, except that the nonwoven surface was impregnated with different amounts of organic or inorganic binder. In particular, the amount of inorganic binder was increased to achieve final densities of (i) 60, (ii) 90, and (iii) 390 kg / m³. 3 Using a nonwoven mat and an organic binder, the final density is (iv) 60 kg / m³ 3 Figure 1 shows the deformation rate (%) under pressure for the nonwoven mat. The results show that organic binders and inorganic binders have different effects on the mechanical properties of the nonwoven mat. The results also show that the mechanical properties of the nonwoven mat change depending on the amount of inorganic binder.

[0143] Example 2: Preparation of colloidal silica, a mixture of colloidal silica and a polymer binder, and a nonwoven mat impregnated with the polymer binder. Nonwoven mats were prepared according to the procedure described in Example 1, except that (i) colloidal silica, (ii) a mixture of colloidal silica and a polymeric organic binder, and (iii) and (iv) the polymeric organic binder were impregnated (see Figure 3 below). A polymeric organic binder was prepared in water from vinyl acetate monomer and ethylene monomer (Vinnapass® EN 428). The deformation rate (%) of the nonwoven mats under pressure was examined, and (i) the density of the mat impregnated only with the inorganic binder was 167 kg / m³. 3 (ii) Nonwoven mat, (ii) Impregnated with inorganic binder and polymer organic binder with a density of 231 kg / m³ 3 (iii) Nonwoven mat impregnated with a polymer organic binder, density 85 kg / m 3 (iv) Nonwoven mats, and (iv) polymer organic binders impregnated with a density of 60 kg / m³ 3 The results for the nonwoven mat are shown in Figure 3. The results show that the method of the present invention yields a nonwoven mat with adjustable mechanical properties. Furthermore, a nonwoven mat impregnated with a mixture of an inorganic binder and a polymeric organic binder exhibits deformation characteristics intermediate between those impregnated with only an inorganic binder and those impregnated with only a polymeric organic binder.

[0144] Example 3: Preparation of a nonwoven mat containing two types of fibers

[0145] A nonwoven mat was prepared according to the procedure described in Example 1, except that approximately 50% of the total weight of the fibers consisted of artificial inorganic fibers having hydroxyl groups (OH) on their surface, and approximately 50% of the total weight of the fibers consisted of the same type of fiber without hydroxyl groups (OH) on its surface. The applicants observed that using the two types of fibers described above improved the deformation response of the nonwoven mat under pressure. Furthermore, using these two types of fibers resulted in fewer defects in the nonwoven mat compared to using only one type of fiber (in particular, the amount of defects on the surface was reduced, resulting in a smoother surface, for example).

[0146] Example 4: Preparation of a nonwoven mat impregnated with the same binder except for using different suction rates.

[0147] Except for using different suction rates (expressed as a percentage of the total capacity of the vacuum pump used for suction) in the process of impregnating the binder, the same procedure as in Example 1 was followed to produce nonwoven mats with the same density. In this example, all samples were impregnated into the same binder composition containing a polymer binder (Vinnapass® EAF68). The deformation rate (%) of the nonwoven mats under pressure was examined, and the results are shown in Table 1 below.

[0148] [Table 1]

[0149] Table 1 shows that even if the final density of the nonwoven mat is the same, the process of impregnating the binder while suctioning affects the final deformation characteristics of the nonwoven mat under pressure.

[0150] Example 5: Fabrication of a battery housing

[0151] A battery housing was fabricated by combining two die-cut sheets made from the nonwoven mat of Example 1. Figure 6 shows a part of the battery housing.

[0152] Example 6: Fabrication of a battery pack

[0153] Multiple batteries are inserted into the battery housing of Example 5 to create a battery pack.

Claims

1. i) - Multiple artificial inorganic fibers having hydroxyl groups (OH) on their surface and an average diameter of 6 microns or more, - Polymer binder, - Solvent and, A step of preparing a dispersion containing the following: ii) A step of forming the dispersed material from step (i) into a web-like structure to obtain a nonwoven surface, iii) A step of drying the nonwoven surface in step (ii) while suctioning until the weight of the solvent on the nonwoven surface is less than 40% by weight of the total weight of the nonwoven surface. iv) A step of impregnating the nonwoven surface of step (iii) with a mixture containing at least one binder while suctioning, in order to obtain a permeated nonwoven surface, and v) A step of heating the permeable nonwoven surface obtained in step (iv) at a temperature of 30 to 300°C to obtain a nonwoven mat. A nonwoven mat for heat insulation and fire protection obtained by a method comprising the above.

2. The nonwoven mat according to claim 1, wherein the weight of the polymer binder in step (i) is 4% by weight or more and 10% by weight or less of the total weight of the dispersion.

3. The nonwoven mat according to claim 1 or 2, wherein at least one of the binders in the mixture of step (iv) is an inorganic binder.

4. The nonwoven mat according to claim 3, wherein the inorganic binder is selected from silica, alumina, aluminum phosphate, sodium silicate, or a mixture thereof, and is preferably colloidal silica.

5. The nonwoven mat according to any one of claims 1 to 4, wherein the mixture in step (iv) contains an organic binder.

6. The nonwoven mat according to claim 5, wherein the organic binder is selected from a dispersion containing polyvinyl alcohol, ethylene, vinyl acetate, or a mixture thereof.

7. The polymer binder in step (i) is one of the following: poly(methyl methacrylate) (PMMA), polycarbonate (PC), polystyrene (PS), polypropylene (PP), polyethylene (PE), polyglycolide (PGA), poly(propylene fumarate) (PPF), polycyanoacrylate (PCA), polycaprolactone (PCL), poly(glycerol sebacate) (PGS), poly(glycerol acrylate sebacate) (PGSA), polyvinylidene fluoride (PVDF), polyvinylidene chloride (PVDC), polybutylene terephthalate (PBT), polyphenylene oxide (PPO), polyvinyl chloride (PVC), cellulose acetate (CA), cyclic olefin copolymer (COC), ethylene vinyl acetate (EVA), ethylene vinyl alcohol (EVOH), polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), A nonwoven mat according to any one of claims 1 to 6, selected from the list of perfluoroalkoxy (PEA), ethylene tetrafluoroethylene (ETFE), polyethersulfone (PES), chlorinated polyethylene (CPE), polylactic acid (PLA), poly(3-hydroxybutyric acid) (P3HB), butylene polyadipate (PBA), ethylene polyadipate (PEA), polybutylene succinate (PBS), polyphenylene sulfide (PPS), polysulfone (PSU), polytrimethylene terephthalate (PTT), polyurethane (PU), polyvinyl acetate, polyvinylidene chloride (PVDC), styrene acrylonitrile (SAN), polyether ketone (PEEK), polyvinyl alcohol (PVA), polyhydroxyethyl methacrylate (PHEMA), poly(N-isopropylacrylamide) (PNIPAAm), and mixtures thereof.

8. The nonwoven mat according to claim 7, wherein the polymer binder in step (i) is poly(vinyl alcohol).

9. The nonwoven mat according to any one of claims 1 to 8, wherein the artificial inorganic fiber having a hydroxyl group (OH) on its surface further comprises Al and Si.

10. The nonwoven mat according to any one of claims 1 to 9, wherein the dispersion in step (i) further contains artificial inorganic fibers that do not have hydroxyl groups (OH) on their surface.

11. The nonwoven mat according to claim 10, wherein the artificial inorganic fibers having hydroxyl groups (OH) on their surface in the dispersion of step (i) constitute more than 30% by weight of the total artificial inorganic fibers in the dispersion.

12. Density of 20-1000 kg / m³ ３ The nonwoven mat according to any one of claims 1 to 11.

13. The nonwoven mat according to any one of claims 1 to 12, wherein the dispersion of step (i) or the mixture of step (iv) further contains at least one aerogel.

14. The nonwoven mat according to any one of claims 1 to 13, wherein the dispersion of step (i) or the mixture of step (iv) further contains silicone or polysiloxane.

15. The nonwoven mat according to any one of claims 1 to 14, wherein the dispersion of step (i) or the mixture of step (iv) further contains a flame retardant.

16. The nonwoven mat according to any one of claims 1 to 15, wherein the polymer binder in step (i) is not a polymer fiber.

17. i) - Multiple artificial inorganic fibers having hydroxyl groups (OH) on their surface and an average diameter of 6 microns or more, - Polymer binder, - Solvent and, A step of preparing a dispersion containing the following: ii) A step of forming the dispersed material from step (i) into a web-like structure to obtain a nonwoven surface, iii) A step of drying the nonwoven surface in step (ii) while suctioning until the weight of the solvent on the nonwoven surface is less than 40% by weight of the total weight of the nonwoven surface. iv) A step of impregnating the nonwoven surface of step (iii) with a mixture containing at least one binder while suctioning, in order to obtain a permeated nonwoven surface, and v) A step of heating the permeable nonwoven surface obtained in step (iv) at a temperature of 30 to 300°C to obtain a nonwoven mat. A method for manufacturing a nonwoven mat for heat insulation, comprising the features described above.

18. A partition member configured to form a partition between two battery cells, or between a single battery cell and a member other than the single battery cell, A partition member comprising at least one nonwoven mat according to any one of claims 1 to 16.

19. A battery housing comprising at least one partitioned opening for housing at least one battery cell, A battery housing comprising the partition member described in claim 18 and / or the nonwoven mat described in any one of claims 1 to 16.

20. The battery housing according to claim 19, manufactured by combining one or more die-cut sheets, preferably by combining one or more die-cut sheets made of the nonwoven mat.

21. Use of a nonwoven mat according to any one of claims 1 to 16, a partition member according to claim 18, or a battery housing according to claim 19 or 20 for thermal insulation, preferably for thermal insulation of a battery, more preferably for thermal insulation of an electric vehicle battery.

22. Use of a nonwoven mat according to any one of claims 1 to 16, a partition member according to claim 18, or a battery housing according to claim 19 or 20 for fire prevention, preferably for protecting the battery from fire, and more preferably for protecting the battery of an electric vehicle from fire.

23. - Multiple batteries, - The partition member according to claim 18 and / or the battery housing according to claim 19 or 20, A battery pack equipped with these features.

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