Covering article

Abstract

A light-shielding article is disclosed. The light-shielding article includes a flame-retardant / fire-spread-reducing element including a pair of flexible graphite outer layers and a core, the flexible graphite outer layers being on both sides of the core. The core may include one or more flame-retardant elements or thermal insulating materials. A battery pack including the light-shielding article is also disclosed. The light-shielding article can be applied to any system in which it is desirable to reduce fire spread.

Description

Technical Field

[0001] The present disclosure relates to shielding articles.

Background Art

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

[0003] As lithium-ion batteries become more prevalent in society, the risks associated with using lithium-ion batteries are becoming better known.

Summary of the Invention

Problems to be Solved by the Invention

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

Means for Solving the Problems

[0005] Embodiments disclosed herein relate to battery packs having improved flame retardancy / reduced fire propagation. Such a battery pack includes a battery housing (AKA casing or enclosure). The housing may include a bottom surface, one or more vertical surfaces, and a lid. The battery housing contains a plurality of battery cells. The battery cells are disposed above the bottom surface and below the lid and are further surrounded by one or more vertical surfaces.

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

[0007] The use of the flame retardant element / fire propagation reduction element is not limited to use in a battery pack. This element is applied to any system where it is desirable to reduce fire propagation.

[0008] The subject matter is further disclosed in the detailed description.

Brief Description of the Drawings

[0009]

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Mode for Carrying Out the Invention

[0010] The graphite article (RFPE) disclosed herein is disclosed for use in a battery pack. However, the graphite article disclosed herein has uses in any environment where reduction of fire propagation is desirable, such as a vehicle firewall, insulation or casing of a battery-driven device, an energy storage system, rapid release of an energy shield or a heat insulating element of a heating device.

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

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

[0013] As disclosed herein, a reduced fire propagation element ("RFPE") is disclosed. The RFPE element can be used in conjunction with or inside a battery pack. FIGS. 7-11 show examples of how the RFPE element can be used with respect to the battery pack. FIG. 9 shows that the RFPE may be disposed on one or more outer surfaces of the battery cells 701, for example, between adjacent vertical faces of adjacent battery cells 701, on the outer surface of the lid of the housing, and on the outer surface of the bottom face of the housing.

[0014] Optionally, the RFPE may be applied to two or more faces of the battery housing 702. As shown in FIG. 10, a first RFPE may be applied to the outer surface of the lid, a second RFPE may be applied to the outer surface of the bottom face, and a third RFPE may be applied to each vertical face of the housing 702, which may be internal (shown) or external (not shown). The use of more than one RFPE on the battery housing 702 is not limited to the examples listed and is merely illustrative of possibilities.

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

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

[0017] Various embodiments of the RFPE are disclosed herein. Each and every embodiment of the RFPE disclosed herein is equally applicable to the uses discussed above.

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

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

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

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

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

[0023] The RFPE includes a core 102. The core 102 may include a foam and at least one flame retardant material. The plurality of flexible graphite sheets 101 may be disposed on opposite surfaces of the core 102, and the sheets are in minimal direct contact with each other only. Unless otherwise specified, "minimal direct contact with each other" means less than 10% of the total area of one graphite sheet is in direct contact with the other, preferably less than 5% of the total area of one graphite sheet is in direct contact with the other. Preferably, the flexible graphite sheets 101 are not in contact with each other. By minimizing or eliminating this direct contact, heat transfer from the high-temperature side to the low-temperature side of the RFPE is avoided.

[0024] The thickness of the core 102 may vary depending on the application of the RFPE. The thickness may be limited due to space constraints in a particular device. Another factor that may be related to the thickness is the insulation value (R-value) of the core 102. If higher insulation is desired, the thickness of the core 102 may be increased and may also be decreased depending on the R-value of the material of the structure of the core 102.

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

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

[0027] Non-limiting examples of suitable ceramic precursors may include silicon carbide (SiC), silicon oxycarbide (SiO x C y ), silicon nitride (Si 3 N 4 ), silicon carbonitride (Si 3+x N 4 C x+y ), and silicon generating compounds such as silicone foams formed from at least one of silicon nitride combinations.

[0028] One embodiment of the foam includes 30% or less NBR, 30% or less PVC, and 30% or less ceramic precursor. In this example, the percentages are weight percentages.

[0029] The foam does not necessarily have to be, or may be, a syntactic foam, an open-cell foam, or a closed-cell foam.

[0030] Other constituent materials for the core foam include foam elastomers and / or thermoplastic elastomer mixtures based on styrenic organic polymers and chlorinated organic polymers. The foam elastomer or thermoplastic elastomer mixture itself includes a styrene-substituted organic polymer, preferably a styrene-butadiene polymer. The styrene-substituted polymer exhibits a styrene content of at least 10%, preferably at least 17%, particularly preferably 20% or more (bound styrene according to ASTM D5775). The styrene-substituted organic polymer is present in the formulation at least 30 phr (per hundred rubber, the amount per 100 weights of rubber, which means it represents at least 30 percent of the elastomer content of the claimed material), preferably at least 50 phr, particularly preferably at least 70 phr.

[0031] The elastomer or thermoplastic elastomer mixture further includes at least 10 phr, preferably at least 30 phr, particularly preferably at least 50 phr of a thermoplastic or thermoplastic elastomeric chlorinated organic polymer (related to the styrene-substituted polymer), preferably polyvinyl chloride (PVC), chlorinated polyethylene (CPE, CM), chlorosulfonated polyethylene (CSM) or any mixture thereof. Further, the elastomer or thermoplastic elastomer mixture includes at least 30 phr, preferably 50 phr, particularly 70 phr of a halogenated paraffin, a halogenated fatty acid-substituted glycerin or any combination thereof (representing an oil and / or a fat and / or a wax), preferably chlorinated paraffin and / or a chlorinated fatty acid-substituted glycerin, particularly preferably a long-chain chlorinated paraffin (C>17) and / or a glycerin substituted with a fatty acid having at least C>8 each. The degree of chlorination of the chlorinated paraffin and / or the fatty acid-substituted glycerin is at least 15 percent, preferably at least 20 percent, particularly preferably at least 30 percent.

[0032] The elastomer or thermoplastic elastomer mixture may also contain an inorganic filler in an amount of at least 30 phr, preferably at least 100 phr, particularly preferably more than 200 phr, preferably having the properties of a metal and / or metalloid chalcogen (i.e., a compound of oxygen, sulfur). The inorganic filler may be an aluminum compound such as aluminum silicate, an oxide, a hydroxide, etc., such as ATH (aluminum trihydroxide) and / or a silicate, a silicone compound such as quartz, zeolite, etc., or a mineral such as gypsum, clay, perlite, vermiculite, chalk, slate, graphite, talc / mica, etc., or a mixture thereof.

[0033] The elastomer or thermoplastic elastomer mixture is foamed into a mainly closed-cell foam having a density of less than 100 kg / m 3 <, preferably less than 65 kg / m 3 <, particularly preferably less than 50 kg / m 3 <, in order to reduce the thermal conductivity to less than 0.075 W / mK at 0 °C, preferably less than 0.040 W / mK at 0 °C, particularly preferably less than 0.035 W / mK at 0 °C, in accordance with EN12667 and ISO845.

[0034] Examples of embodiments of the foamed polymer material can contain components in an amount of at least 300 phr but less than 1000 phr in total, including at least two types of polymers of 100 phr, among which (1) at least 55 phr is polyvinyl chloride (PVC) or a vinyl chloride copolymer or a vinyl chloride terpolymer or a mixture thereof, and (2) at least 10 phr is at least one additional chlorinated organic polymer crosslinked by sulfur and / or a metal oxide and / or a thiadiazole derivative.

[0035] The elastomer or thermoplastic elastomer mixture may contain additional additives such as flame retardants and synergists, biocides, plasticizers, stabilizers (e.g., against UV, ozone, reversion, etc.), colorants, etc. in any ratio, e.g., additives for improving its manufacturing, use, aspects, and performance characteristics, inhibitors, retardants, accelerators, etc.; and / or additives that conform to the requirements of the use, e.g., char-forming additives and / or intumescent additives such as intumescent graphite that cause the material to self-expand during a fire (e.g., for general protection purposes and / or for closing and protecting penetrations in sidewalls and partition sidewalls); and / or substances such as boron compounds, silicon-containing compounds that self-ceramize at pipe and sidewall penetrations, etc. in case of a fire; and / or internal adhesion promoters such as silicate esters, functional silanes, polyols, etc. to ensure self-adhesion in co-extrusion and co-lamination applications.

[0036] In embodiments for enhancing sufficient fire resistance and low smoke generation, the use of non-halogenated polymers should be limited to less than 30 phr, preferably less than 20 phr, particularly preferably less than 10 phr. The achievable amount of non-halogenated polymers depends on the required fire and smoke performance and the required dimensions and density of the material due to the impact on the fire load.

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

[0038] Suitable characteristics of the expandable graphite include an onset temperature of at least about 160°C. Typically, the onset temperature is 350°C or less. A typical onset temperature can be at least about 180°C, at least about 200°C, at least about 220°C, at least about 250°C or at least about 280°C.

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

[0040] A suitable fill level of the core 102 having expandable graphite may include at least about 2 weight percent (pbw) of the expandable graphite. The maximum loading level may be up to about 50 (50%) pbw. Any range from 2 weight percent to 50 weight percent, such as, for example, 2 - 40 weight percent, 2 - 30 weight percent, 2 - 20 weight percent, 2 - 10 weight percent, 5 - 40 weight percent, 5 - 30 weight percent, 5 - 20 weight percent, 5 - 10 weight percent, etc. is acceptable. Pbw is used herein to mean weight percent of the entire article.

[0041] According to the present disclosure, the flexible graphite sheet 101 may be attached to the core 102. Preferably, the flexible graphite sheet 101 is adhered to the core 102. Any suitable type of adhesive can be used. The above description regarding the adhesive is incorporated herein. Optionally, a refractory adhesive may be used to adhere each flexible graphite sheet 101 to the core 102 as needed. In a further option, a refractory adhesive may be used to adhere one side of the flexible graphite sheet 101 to the core 102, and a non-refractory adhesive may be used together with the other flexible graphite sheet 101 to adhere it to the core 102. In embodiments where two types of adhesives are used, the non-refractory adhesive preferably adjoins the surface of the battery housing 602. In other words, the refractory adhesive adjoins the plurality of battery cells 601.

[0042] Preferably, the RFPE does not have one or more structural supports between the flexible graphite sheets 101. This description applies to all embodiments of the RFPE disclosed herein, as well as those contemplated within the scope of the present disclosure.

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

[0044] The RFPE400 of the present disclosure shown in FIG. 4 may include an insulating material as the outer layer 201 and may include flexible graphite as the core layer 101. In another embodiment shown in FIG. 2, the RFPE200 includes at least one flexible graphite sheet 101 attached to the insulating layer 201. In another embodiment shown in FIG. 3, in the RFPE300, the flexible graphite sheet 101 (not shown in FIG. 3) of the RFPE200 may be replaced with or used in combination with a graphite-doped silicone layer 301 adjacent to the insulating layer 201. The graphite additive for doping the silicone layer may include graphite powder, expandable graphite powder, or a combination thereof.

[0045] The RFPE500 shown in FIG. 5 may include a metal backing layer 501 adjacent to one of the flexible graphite sheets 101. Suitable types of metals include steel, aluminum, copper, and their alloys. The RFPE600 shown in FIG. 6 may include an electrical insulating layer 601. In any embodiment including the electrical insulating layer 601, the electrical insulating layer 601 is the outermost layer. An example of a material suitable for forming the electrical insulating layer 601 may include polyimide.

[0046] An advantage of the RFPE disclosed herein is an improvement in the suppression of fire propagation. The RFPE disclosed herein can be used to provide up to 50 minutes of suppressed fire propagation in a manufactured article at a temperature of up to 350°C.

[0047] Examples The reduction of fire propagation of various samples was tested.

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

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

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

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

[0052]

Table 1

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

[0054] The temperature curves of each sample and the control are shown in FIGS. 13A - 13E and 14.

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

[0056] The disclosures of all cited patents and publications referred to in this application are hereby incorporated by reference in their entirety. The various embodiments disclosed herein can be implemented in any combination thereof. The above description is intended to enable one of ordinary skill in the art to practice the invention. It is not intended to detail all possible variations and modifications that will be apparent to one of ordinary skill in the art upon reading the description. However, all such modifications and variations are intended to be included within the scope of the invention as defined by the following claims. The claims are intended to cover the indicated elements and steps in any arrangement or sequence that is effective to meet the objects of the invention for which it is intended, unless the context clearly indicates otherwise.

[0057] All criteria for a single characteristic or limitation of this disclosure are to be considered as including the corresponding plural characteristics or limitations, unless otherwise specified or the context clearly suggests the contrary, and vice versa. Thus, in this disclosure, the words "a" or "an" should be construed as including both the singular and the plural. Conversely, references to a plurality of items are to be considered as including the singular where appropriate.

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

[0059] If not otherwise described herein, thermal conductivity is provided at room temperature and standard pressure (1 atmosphere) or alternatively, if standard test protocols such as ASTM D5470 for the in-plane conductivity of flexible graphite articles are known, provided under appropriate test conditions.

[0060] All combinations of methods or process steps used herein can be performed in any order unless otherwise specified in the context in which the referenced combination is made or unless it is otherwise clearly implied that the combination cannot be performed in a different order.

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

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

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

[0064] Exemplary embodiments

[0065] 1.a. A first and a second flexible graphite sheet, each flexible graphite sheet having a thickness of at least 0.25 mm and a thermal conductivity of at least 300 W / mK, b. A core comprising a foam and at least one flame retardant material, comprising wherein the flexible graphite sheets disposed on opposite surfaces of the core are in minimal direct contact with each other article.

[0066] 2. The article according to exemplary embodiment 1, wherein the thickness of the core is 10 mm or less The article according to exemplary embodiment 1.

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

[0068] 4. The ceramic precursor is a compound selected from the group consisting of silicon carbide (SiC), silicon oxycarbide (SiO x C y ), silicon nitride (Si 3 N4 )), silicon carbonitride (Si 3+x N 4 C x+y ), and silicon nitride (SiN x N y ), and at least one of combinations thereof, the article according to exemplary embodiment 3 described.

[0069] 5. The thickness of the core is 5 mm or less, and the thickness of each of the flexible graphite sheets is at least 0.5 mm the article according to exemplary embodiment 1, 2, 3 or 4.

[0070] 6. The flame retardant contains expandable graphite the article according to exemplary embodiment 1, 2, 3, 4 or 5.

[0071] 7. The filling level of expandable graphite is at least 2% by weight the article according to exemplary embodiment 6.

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

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

[0074] 10. The onset temperature of expandable graphite is less than 350 °C the article according to exemplary embodiment 6, 7 or 8.

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

[0076] 12. The mesh contains meshes of 20 or less the article according to exemplary embodiment 6, 7, 8, 9, 10 or 11. ​

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

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

[0079] 15. Having no one or more structural supports between flexible graphite sheets The article according to any one of exemplary embodiments 1 to 14.

[0080] 16.a. A first and a second flexible graphite sheet, each flexible graphite sheet having a thickness of at least 0.25 mm and a thermal conductivity of at least 300 W / mK, and b. A core including at least one flame retardant material and a heat insulating material including at least one of mica, aerogel, woven mesh, silicone resin, glass fiber, carbon fiber, mineral wool, gypsum board, concrete, titanium, nickel alloy and combinations thereof, and at least one flame retardant material, and Comprising, The flexible graphite sheets disposed on opposite surfaces of the core are in minimal direct contact with each other. Article.

[0081] 17. The core has a thickness of 5 mm or less, and each thickness of the flexible graphite sheets is at least 0.5 mm. The article according to exemplary embodiment 16.

[0082] 18. The flame retardant contains expandable graphite. The article according to exemplary embodiment 16.

[0083] 19. The filling level of the expandable graphite is at least 2% by weight. The article according to exemplary embodiment 18.

[0084] 20. The filling level of the expandable graphite is 50% by weight or less. The article according to exemplary embodiment 18.

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

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

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

[0088] 24. The mesh includes a mesh of 20 or less. The article according to exemplary embodiment 18, 19, 20, 21, 22 or 23.

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

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

[0091] 27. There is no one or more structural supports between the flexible graphite sheets. The article according to any one of exemplary embodiments 16 - 26.

[0092] 28.a. A first and a second flexible graphite sheet, each having a thickness of at least 0.10 mm and a thermal conductivity of at least 300 W / mK, and b. A core including a foam and at least one flame retardant material, comprising, wherein the flexible graphite sheets disposed on opposite surfaces of the core are in minimal direct contact with each other article.

[0093] 29. The article according to exemplary embodiment 28, wherein the thickness of the core is 10 mm or less. The article according to exemplary embodiment 28.

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

[0095] 31. The article according to exemplary embodiment 30, wherein the ceramic precursor includes at least one of the following compounds: silicon carbide (SiC), silicon oxycarbide (SiO x C y ), silicon nitride (Si 3 N 4 ), silicon carbonitride (Si 3+x N 4 C x+y ), silicon oxynitride (SiO x N y ), and combinations thereof. The article according to exemplary embodiment 30.

[0096] 32. The article according to any one of exemplary embodiments 28 to 31, wherein the thickness of the core is 5 mm or less and the thickness of each flexible graphite sheet is at least 0.5 mm. The article according to any one of exemplary embodiments 28 to 31.

[0097] 33. The article according to exemplary embodiment 32, wherein the flame retardant includes expandable graphite. The article according to exemplary embodiment 32.

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

[0099] 35. The loading level of the expandable graphite is 50% by weight The article according to exemplary embodiment 33

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

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

[0102] 38. The expandable graphite has a size of at least 325 mesh The article according to any one of exemplary embodiments 33 to 37

[0103] 39. The mesh includes a mesh of 20 or less The article according to any one of exemplary embodiments 33 to 38

[0104] 40. The flame retardant includes at least one other flame retardant in addition to the expandable graphite The article according to any one of exemplary embodiments 33 to 38

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

[0106] 42. There is no one or more structural supports between the flexible graphite sheets The article according to any one of exemplary embodiments 28 to 41.

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

[0108] 44. The insulating layer is talc, mica, aerogel, woven mesh, silicone resin, glass fiber, carbon fiber, ceramic fiber, ceramic wool, mineral wool, gypsum board, concrete, titanium, nickel alloy, and combinations thereof The composite article according to exemplary embodiment 43.

[0109] 45. The insulating layer includes a completely dense insulator The composite article according to exemplary embodiment 43.

[0110] 46. The insulating layer includes a refractory material The composite article according to exemplary embodiment 43.

[0111] 47. The thickness of the insulating layer is from at least about 100 microns to about 10 mm The composite article according to any one of exemplary embodiments 43 to 46.

[0112] 48. The thickness of the insulator is at least 1 mm The composite article according to any one of exemplary embodiments 43 to 47.

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

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

[0115] 51. The alloy contains nitride. The composite article according to exemplary embodiment 50.

[0116] 52. Further includes a second insulating layer disposed adjacent to the flexible graphite layer, and the graphite forms the core of the composite. The composite article according to any one of exemplary embodiments 43 to 51.

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

[0118] 54. The second insulating layer includes a completely dense insulator. The composite article according to exemplary embodiment 53.

[0119] 55. The second insulating layer includes a refractory material. The composite article according to exemplary embodiment 54.

[0120] 56. The thickness of the second insulating layer is from at least about 100 microns to about 10 mm. The composite article according to any one of exemplary embodiments 52 to 55.

[0121] 57. The thickness of the second insulator is at least 1 mm. The composite article according to any one of exemplary embodiments 52 to 56.

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

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

[0124] 60. The alloy contains nitride. The composite article according to exemplary embodiment 59.

[0125] 61. The insulating layer does not contain an organic binder. The composite article according to any one of exemplary embodiments 43 to 55.

[0126] 62. The second insulating layer does not contain an organic binder. The composite article according to any one of exemplary embodiments 53 to 61.

[0127] 63. Further includes a metal backing layer and includes the composite article according to any one of exemplary embodiments 43 to 62. Shielding article.

[0128] 64. Further includes an outermost layer that electrically insulates. The shielding article according to exemplary embodiment 63.

[0129] 65. a. A battery housing having two or more surfaces, b. A plurality of battery cells disposed within the battery housing, c. In contact with at least one of two or more surfaces of the battery housing, The article according to any one of exemplary embodiments 43 to 63, and A battery pack comprising.

[0130] 66. The article is disposed on either the inner or outer side of the surface of the battery housing. The battery pack according to exemplary embodiment 65.

[0131] 67. a. A battery housing having two or more surfaces, b. A plurality of battery cells disposed within the battery housing, c. The first and second articles according to any one of exemplary embodiments 43 to 64, comprising, The first article is in contact with at least one of two or more surfaces of the battery housing, The second article is in contact with a surface of the battery housing that is different from the surface with which the first article is in contact. Battery pack.

[0132] 68. a. A battery housing having two or more surfaces, b. A plurality of battery cells disposed within the battery housing, c. The first and second articles according to any one of exemplary embodiments 43 to 64, comprising, The first article is in contact with at least one of two or more surfaces of the battery housing, The second article is disposed between two adjacent battery cells. Battery pack.

[0133] 69. a. A battery housing having two or more surfaces, b. A plurality of battery cells disposed within the battery housing, c. An article according to any one of the exemplary embodiments in contact with at least one of two or more surfaces of the battery housing, Battery pack comprising. An article according to any one of the exemplary embodiments.

[0134] 70. The article is disposed on either the inner or outer side of the surface of the battery housing. The battery pack according to exemplary embodiment 69.

[0135] 71. a. A battery housing having two or more surfaces, b. A plurality of battery cells disposed within the battery housing, c. The first and second articles according to any one of claims 1 to 4, comprising, The first article is in contact with two or more surfaces of the battery housing, The second article is in contact with a surface of the battery housing different from the surface with which the first article is in contact A battery pack comprising.

[0136] 72. a. A battery housing having two or more surfaces, b. A plurality of battery cells disposed within the battery housing, c. The first and second articles according to any one of claims 1 to 4, comprising, The first article is in contact with two or more surfaces of the battery housing, The second article is disposed between two adjacent battery cells A battery pack.

Claims

1. a. First and second flexible graphite sheets, each having a thickness of at least 0.25 mm and a thermal conductivity of at least 300 W / mK; b. A core comprising a foam and at least one flame retardant material; comprising: The first and second flexible graphite sheets disposed on opposing surfaces of the core are in minimal direct contact with each other. An article.

2. A shielding article comprising the article according to Claim 1, further comprising a metal backing layer.

3. a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. A first article according to the article of Claim 1 and a second article according to the article of Claim 1; comprising: The first article is in contact with at least one of two or more surfaces of the battery housing; The second article is in contact with a surface of the battery housing different from the surface with which the first article is in contact. A battery pack.

4. a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. A first article according to the article of Claim 1 and a second article according to the article of Claim 1; comprising: The first article is in contact with at least one of two or more surfaces of the battery housing; The second article is disposed between two adjacent battery cells. A battery pack.

5. a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. The article according to Claim 1, in contact with at least one of two or more surfaces of the battery housing. A battery pack.

6. a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. A first article according to the article of Claim 1 and a second article according to the article of Claim 1; comprising: The first article is in contact with two or more surfaces of the battery housing; The second article is in contact with a surface of the battery housing different from the surface with which the first article is in contact. A battery pack.

7. a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. A first article related to the article according to claim 1 and a second article related to the article according to claim 1, comprising: wherein the first article contacts two or more surfaces of the battery housing; the second article is disposed between two adjacent battery cells battery pack.

8. a. First and second flexible graphite sheets, each flexible graphite sheet having a thickness of at least 0.25 mm and a thermal conductivity of at least 300 W / mK; b. A core comprising a heat insulating material including at least one of mica, aerogel, woven mesh, silicone resin, glass fiber, carbon fiber, mineral wool, gypsum board, concrete, titanium, nickel alloy, and combinations thereof, and at least one flame retardant material; comprising: the first and second flexible graphite sheets disposed on opposite surfaces of the core are in minimal direct contact with each other article.

9. A shielding article comprising the article according to claim 8, further comprising a metal backing layer.

10. a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. A first article related to the article according to claim 8 and a second article related to the article according to claim 8; comprising: the first article contacts at least one of two or more surfaces of the battery housing; the second article contacts a surface of the battery housing that is different from the surface contacted by the first article battery pack comprising.

11. a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. A first article related to the article according to claim 8 and a second article related to the article according to claim 8; comprising: the first article contacts at least one of two or more surfaces of the battery housing; the second article is disposed between two adjacent battery cells battery pack.

12. a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. The article according to claim 8, which contacts at least one of two or more surfaces of the battery housing; battery pack comprising.

13. a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. A first article according to the article of claim 8 and a second article according to the article of claim 8; comprising; the first article is in contact with two or more surfaces of the battery housing; the second article is in contact with a surface of the battery housing that is different from the surface with which the first article is in contact A battery pack comprising. **Claim 14** An insulating layer having a thickness of at least 10 microns and capable of withstanding a temperature of at least 350° C. for at least 50 minutes in an oxygen environment; Any one of a flexible graphite layer or a graphite-doped silicone composite having a thickness of at least 0.25 mm and a thermal conductivity of at least 300 W / mK; A composite article comprising. **Claim 15** A shielding article comprising the composite article according to claim 14, further comprising a metal backing layer. **Claim 16** a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. A first article according to the composite article of claim 14 and a second article according to the composite article of claim 14; comprising; the first article is in contact with at least one of the two or more surfaces of the battery housing; the second article is in contact with a surface of the battery housing that is different from the surface with which the first article is in contact A battery pack. **Claim 17** a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. A first article according to the composite article of claim 14 and a second article according to the composite article of claim 14; comprising; the first article is in contact with at least one of the two or more surfaces of the battery housing; the second article is disposed between two adjacent battery cells A battery pack. **Claim 18** a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. The composite article according to claim 14, which is in contact with at least one of the two or more surfaces of the battery housing; A battery pack comprising. **Claim 19** a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. A first article according to the composite article of claim 14 and a second article according to the composite article of claim 14, comprising: wherein the first article contacts two or more surfaces of the battery housing; and the second article contacts a surface of the battery housing different from the surface contacted by the first article. A battery pack comprising the above. **Claim 20** a. A battery housing having two or more surfaces; b. A plurality of battery cells disposed within the battery housing; c. A first article according to the composite article of claim 14 and a second article according to the composite article of claim 14, comprising: wherein the first article contacts two or more surfaces of the battery housing; and the second article is disposed between two adjacent battery cells. A battery pack.

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