Articles with thermal insulation properties

Abstract

The present disclosure relates to a cushioning article comprising a non-syntactic polymer foam layer and a plurality of spacer elements disposed within the polymer foam layer, each spacer element being at least partially embedded within the polymer foam layer, and each spacer element having a size greater than 200 micrometers.

Description

[Technical Field]

[0001] This disclosure relates in general to the field of cushioning articles, and more specifically to the field of cushioning articles having thermal insulation properties. This disclosure also relates to methods for manufacturing such cushioning articles and their use for industrial applications, in particular for thermal management applications in the transportation industry. [Background technology]

[0002] The electrification of automobiles is currently one of the biggest trends in the automotive industry. This trend has made the development of electric vehicle batteries, suitable as propulsion and energy storage devices, a major focus in the automotive industry. Electric vehicle batteries are used to power the propulsion systems of battery electric vehicles (BEVs) and hybrid electric vehicles (HEVs). These batteries are typically lithium-ion batteries and are designed with high ampere-hour capacities. The development of electric vehicle batteries is progressing towards increasing the energy density (kWh / kg) within the battery, enabling longer range coverage and shorter battery charging times.

[0003] Due to the high energy density of electric vehicle batteries and the high energy flow during charging or discharging, there is a risk of hot spots and thermal runaway events occurring, where heat generated by the decomposition of battery cells propagates very rapidly to adjacent cells. This chain reaction can lead to explosions or fires throughout the entire electric vehicle.

[0004] Furthermore, during the normal lifecycle of these energy storage devices, particularly during the fast charging and discharging cycles of batteries in electric vehicles, the battery cells used in such battery modules tend to continuously expand and contract. These expansion / contraction cycles can place the battery cells under considerable pressure conditions, which in turn can lead not only to mechanical damage to the battery cells but also to other issues.

[0005] In this context, the use of thermal management solutions has rapidly emerged as a way to mitigate the temperature rise of battery assemblies. One partial solution is disclosed in U.S. Patent Application Publication 2007 / 0259258(A1) (Buck), which describes the use of a heat-absorbing material to absorb the heat generated by the battery cells in the battery pack assembly and transfer the heat out of the assembly case, thereby maintaining a lower temperature inside each battery pack and the entire battery assembly. Another partial solution is described in U.S. Patent Application Publication 2019393574(A1) (Goeb et al.), which describes the use of a thermally conductive gap filler composition containing a thermally conductive filler material to cool the battery assembly. Another partial solution is described in U.S. Patent Application Publication No. 2016 / 0308186(A1)(Han), which discloses a battery module comprising battery cells arranged adjacent to one another along a first direction, spacers between adjacent battery cells, and multilayer insulating sheets between adjacent battery cells together with the spacers, the multilayer insulating sheets comprising multiple insulating layers extending parallel to the surfaces of the battery cells. [Overview of the project]

[0006] In one embodiment, the present disclosure relates to a buffer article comprising a non-syntactic polymer foam layer and a plurality of spacer elements disposed within the polymer foam layer, wherein each spacer element is at least partially embedded within the polymer foam layer and each spacer element has a size greater than 200 micrometers (its maximum dimension).

[0007] In another aspect, the present disclosure relates to a method for manufacturing the above-mentioned buffer article, comprising the steps of: providing the above-mentioned polymer foam layer; providing the above-mentioned plurality of spacer elements; and incorporating the plurality of spacer elements into the polymer foam layer so that the plurality of spacer elements are arranged in the polymer foam layer and each spacer element is at least partially embedded in the polymer foam layer.

[0008] In another aspect, this disclosure relates to the use of the aforementioned cushioning articles in the transportation industry for industrial applications, particularly for thermal management applications. [Brief explanation of the drawing]

[0009] [Figure 1] This is a schematic diagram of an exemplary coating apparatus and method for producing an exemplary polymer foam layer for use in the present disclosure. [Figure 2] This is a schematic diagram of an exemplary coating apparatus and method for manufacturing a buffer article according to an exemplary aspect of the present disclosure. [Figure 3] This is a side cross-sectional view of an exemplary buffer article according to an exemplary embodiment of the present disclosure. [Figure 4] This is a side cross-sectional view of an exemplary buffer article according to an exemplary embodiment of the present disclosure. [Figure 5] This is a side cross-sectional view of an exemplary buffer article according to an exemplary embodiment of the present disclosure. [Figure 6] This is a cross-sectional top view of an exemplary buffer article according to an exemplary embodiment of the present disclosure, in which the spacer elements form different patterns along a plane formed by a polymer foam layer. [Figure 7] This is a cross-sectional top view of an exemplary buffer article according to an exemplary embodiment of the present disclosure, in which the spacer elements form different patterns along a plane formed by a polymer foam layer. [Figure 8] An exemplary battery module assembly according to one aspect of the present disclosure is shown. [Modes for carrying out the invention]

[0010] According to a first aspect, the present disclosure relates to a buffer article comprising a non-syntactic polymer foam layer and a plurality of spacer elements disposed within the polymer foam layer, each spacer element being at least partially embedded within the polymer foam layer, and each spacer element having a size greater than 200 micrometers (its maximum dimension).

[0011] In the context of the present disclosure, it has surprisingly been found that the above-mentioned cushioning articles have excellent thermal insulation properties, excellent thermal runaway barrier performance, and excellent compression properties. In some advantageous aspects, the multilayer structure described above further provides excellent heat resistance and stability even upon long-term exposure to temperatures up to 600°C and heat.

[0012] The described multilayer structure is further characterized by one or more of the following advantageous advantages: a) excellent cushioning performance for individual battery cells when used in battery assemblies; b) excellent resistance to high compressive forces and high pressure conditions; c) the ability to maintain the foam structure for the polymer foam layer even under high pressure conditions; d) an easy and cost-effective manufacturing method based on readily available starting materials and minimal manufacturing steps; e) simplicity and versatility of the structure; f) excellent formulation flexibility of the polymer foam layer for use herein; g) excellent structural and design flexibility of the spacer layer into various forms, sizes and shapes; h) the ability to fine-tune the compression properties of the multilayer structure to specific applications, operating conditions and battery cell types; i) excellent pressure distribution to individual battery cells when used in battery assemblies; j) excellent processability and conversion properties; k) low thermal conductivity; l) the ability to be manufactured in relatively thin thicknesses; m) articles that are ready to use particularly for thermal management applications; n) long-term durability of energy storage assemblies using the cushioning articles of the present disclosure; and o) the ability to adhere to various substrates such as metal or polymer surfaces without requiring adhesion-promoting processing steps or compositions.

[0013] These are particularly unexpected findings in many respects. First, good cushioning performance and resistance to high compressive forces and high pressure conditions are considered self-contradicting properties. In addition, it is generally expected that thermal insulation and heat resistance stability cannot be obtained in compressible (soft) polymer foam layers, particularly foam layers having a relatively thin thickness, more specifically foam layers subjected to compression.

[0014] In the context of the present disclosure, the applicant has faced the technical challenge of designing a cushioning structure that provides a delicate balance of excellent compression properties, resistance to high compressive forces, and thermal insulation properties.

[0015] Without being bound by theory, these excellent properties and performance attributes are believed to result from the combination of technical features, specifically the use of (a) a polymer foam layer and (b) a plurality of spacer elements disposed within the polymer foam layer, wherein each spacer element is at least partially embedded in the polymer foam layer, and each spacer element has a size (in its maximum dimension) of greater than 200 micrometers.

[0016] Further without being bound by theory, it is believed that the plurality of spacer elements described above advantageously act as opposing force means to prevent or at least reduce unwanted compressive forces that the polymer foam withstands, not only during normal charging and discharging cycles of batteries in electric vehicles, but also under more extreme conditions such as thermal runaway events. More specifically, it is believed that the plurality of spacer elements described above have the ability to maintain the critical minimum gap between battery cells even under high pressure conditions, while still ensuring the appropriate cushioning properties required to allow battery cells to expand and contract during their life cycle. This ability to maintain this set of properties is believed to directly and advantageously affect the excellent thermal insulation properties provided by the cushioning article of the present disclosure.

[0017] The set of advantageous properties detailed above provided by the multilayer structure described herein is even more surprising when considering that it was expected that the plurality of spacer elements would adversely affect the foam structure of the polymer foam layer, thereby impairing thermal insulation properties. The advantageous thermal insulation properties provided by the cushioning article of the present disclosure are even more counterintuitive when considering that those skilled in the art would actually expect lower performance, due to the fact that the cells contained in the polymer foam layer are replaced by solid spacer elements, particularly those having a relatively large particle size.

[0018] Therefore, the buffer articles are suitable for use in a variety of industrial applications, particularly in thermal management applications. The buffer articles of this disclosure are particularly suitable for thermal management applications in the transportation industry (particularly the automotive industry), especially as thermal barriers, and more specifically as thermal runaway barriers. The buffer articles described herein are remarkably suitable for use as spacers with thermal runaway barrier properties in rechargeable electrical energy storage systems, particularly in battery modules. Advantageously, the buffer articles of this disclosure can also be used in the manufacture of battery modules, particularly electric vehicle battery modules and assemblies. In some advantageous embodiments, the buffer articles described herein are particularly suitable for manual or automated handling and applications, especially high-speed robotic equipment, due to their excellent robustness, dimensional stability, and handling characteristics. In some advantageous embodiments, the buffer articles described can also meet challenging fire control standards due to their remarkable flammability and thermal stability properties.

[0019] In the context of this disclosure, the term “adjacent” means two superimposed films or layers that are directly adjacent to each other, i.e., touching each other, or not directly adjacent to each other, i.e., at least one additional film or layer is positioned between the first two superimposed films or layers. The terms “upper” and “bottom” layers or films are used herein to indicate the position of a layer or film relative to the surface of a substrate supporting such a layer or film in a method for forming a polymer foam layer. The direction in which a movable substrate, layer, or film moves is referred herein to as the downstream direction. The relative terms “upstream” and “downstream” describe positions along the extension of the substrate.

[0020] Furthermore, in the context of this disclosure, the term “neat polymer foam layer” means a polymer foam layer from which spacer elements have been removed.

[0021] The polymer foam layers used herein are not particularly limited. Suitable polymer foam layers for use herein can be readily identified by those skilled in the art in light of this disclosure.

[0022] In an advantageous embodiment, the polymer foam layer for use herein comprises a material having a weight loss of 70% or less, 60% or less, 50% or less, 40% or less, 30% or less, or even 25% or less after 3 minutes at 600°C, as measured according to the thermal stability test method described in the experimental section.

[0023] The polymer foam layers of the type described above are typically called heat-resistant materials or heat-resistant polymer foam layers.

[0024] In exemplary embodiments, a polymer foam layer for use in a multilayer structure of the present disclosure includes a material selected from the group consisting of elastomers, thermoplastics, thermoplastic elastomers, thermoplastic non-elastomers, thermosettings, and any combination or mixture thereof.

[0025] In one advantageous embodiment, the polymer foam layer for use herein includes a material selected from the group consisting of silicone elastomers, fluorosilicone rubbers, aromatic polyamides, polybenzimidazoles, polysulfides, polyimides, polysulfones, polyetherketones, fluorocarbons, polyisoprene, polybutadiene, polychloroprene, polyurethanes, polyolefins (particularly PE, PP, and EVA), polystyrene, and any combination or mixture thereof.

[0026] In a more advantageous embodiment, the polymer foam layer for use herein comprises a material selected from the group consisting of elastomer materials.

[0027] In another, more advantageous embodiment, the polymer foam layer for use herein, when measured according to the compression test methods described in the Experimental Section, achieves a compression value of at least 60% when using compressive forces of 700 kPa or less, 600 kPa or less, 500 kPa or less, 400 kPa or less, 300 kPa or less, 250 kPa or less, 200 kPa or less, 150 kPa or less, 100 kPa or less, 80 kPa or less, 60 kPa or less, or even 50 kPa or less. This type of polymer foam layer is typically referred to as a (relatively highly) compressible polymer foam layer (or flexible polymer foam layer).

[0028] In another, more advantageous embodiment, the polymer foam layer for use herein comprises a material selected from the group consisting of silicone elastomers, particularly silicone rubber, and more specifically, organopolysiloxane polymers.

[0029] In one particularly advantageous aspect of this disclosure, the polymer foam layer for use herein is a silicone rubber foam layer.

[0030] In an advantageous embodiment, a silicone rubber foam layer for use herein can be obtained from a curable foaming precursor, particularly an in-situ foaming precursor composition, for use in this specification.

[0031] The precursor compositions for silicone rubber foams used herein are not particularly limited, as long as they are curable and foamable. Any curable foamable precursor of silicone rubber foams known in the art may be formally used in the context of this disclosure. Suitable curable foamable precursors for silicone rubber foams used herein can be readily identified by those skilled in the art in light of this disclosure.

[0032] In a more advantageous embodiment, the precursor for the silicone rubber foam layer to be used herein is a two-component composition.

[0033] In a typical embodiment, the two-component precursor composition for the silicone rubber foam is selected from the group consisting of addition-curing two-component silicone compositions, condensation-curing two-component silicone compositions, and any combination or mixture thereof.

[0034] In a preferred embodiment, the precursor of the silicone rubber foam for use herein includes an addition-curing two-component silicone composition, particularly an addition-curing two-component organopolysiloxane composition.

[0035] Suitable addition-curing two-component organopolysiloxane compositions for use herein as precursors to silicone rubber foams can be readily identified by those skilled in the art. An example of an addition-curing two-component organopolysiloxane composition for use herein is described, for example, in U.S. Patent No. 4,593,049 (Bauman et al.).

[0036] According to a particularly advantageous aspect of the present disclosure, a precursor for silicone rubber foam to be used herein comprises at least one organopolysiloxane compound A, at least one organohydrogenpolysiloxane compound B containing at least two, particularly at least three, hydrogen atoms per molecule, at least one hydroxyl-containing compound C, an effective amount of curing catalyst D, particularly a platinum-based curing catalyst, and optionally, a foaming agent.

[0037] In exemplary embodiments, at least one organopolysiloxane compound A for use herein has the following formula: [ka] [In the formula, R and R'' are independent of C1~C 30 R is selected from the group consisting of hydrocarbon groups, and in particular R is an alkyl group and phenyl selected from the group consisting of methyl, ethyl, propyl, and trifluoropropyl, and optionally R is a methyl group. R' is C1~C 20The alkenyl group, in particular R', is selected from the group consisting of vinyl, allyl, hexenyl, decenyl, and tetradecenyl, and more specifically R' is a vinyl group. R'' is an alkyl group such as methyl, ethyl, propyl, trifluoropropyl, or phenyl, and in particular R'' is a methyl group. n is an integer with values ​​in the range of 5 to 1000, especially between 5 and 100.

[0038] In another exemplary embodiment, at least one hydroxyl-containing compound C for use herein is selected from the group consisting of alcohols, polyols, particularly polyols having 3 to 12 carbon atoms per molecule and an average of at least 2 hydroxyl groups, silanols, silanol-containing organopolysiloxanes, silanol-containing silanes, water, and any combination or mixture thereof.

[0039] In yet another exemplary embodiment, at least one hydroxyl-containing compound C for use herein is selected from the group consisting of silanol-containing organopolysiloxanes.

[0040] According to an advantageous aspect of this disclosure, the polymer foam layer for use herein is: a) A step of providing a substrate, b) A step of providing a first solid film and applying it onto a substrate, c) A step of providing a coating tool comprising an upstream side and a downstream side, which is offset from the substrate and forms a gap perpendicular to the surface of the substrate, d) A step of moving the first solid film downstream with respect to the coating tool, e) A step of providing a curable (and foamable) precursor of a polymer foam upstream of a coating tool, thereby coating the polymer foam precursor as a layer through gaps on a substrate having a first solid film, f) Providing a second solid film, and applying the second solid film (at least partially) along the upstream side of the coating tool, thereby applying the first solid film and the second solid film simultaneously with the formation of (adjacent) layers of the silicone rubber foam precursor, g) A step of foaming or enabling foaming of a polymer foam precursor, h) A step of curing or enabling the curing of a polymer foam precursor layer to form a polymer foam layer, i) A step of optionally subjecting a polymer foam precursor layer to heat treatment, This can be obtained by a method comprising the step of optionally removing a first solid film and / or a second solid film from the polymer foam layer.

[0041] Figure 1 shows an exemplary method for producing a polymer foam layer (particularly a silicone rubber foam layer) and a schematic diagram of a coating apparatus suitable for use in the production method. The coating apparatus 1 comprises a substrate 2, a coating tool 7 in the form of a coating knife, an unwinding roll 11 and a winding roll 12 for a first solid film 5, and an unwinding roll 9 and a winding roll 10 for a second solid film 6. The downstream direction 8 in which the substrate 2 (with the first solid film 5) moves relative to the coating tool 7 is represented by an arrow with a corresponding reference number.

[0042] In a typical embodiment of this disclosure, a curable foam precursor 3 of the polymer foam is provided upstream of a coating tool 7, thereby coating the polymer foam precursor 3 as a layer through gaps onto a substrate 2 having a first solid film 5. In Figure 1, the curable foam precursor 3 of the polymer foam is represented as forming so-called “rolling beads” upstream of the coating tool 7. A second solid film 6 is applied (at least partially) along the upstream side of the coating tool 7, and the first solid film 5 and the second solid film 6 are applied simultaneously with the formation of the layer of polymer foam precursor 3. The layer of polymer foam precursor 3 can then be foamed and cured into a polymer foam layer 4, which typically comprises the first solid film 5 on its bottom surface and the second solid film 6 on its top surface. Optionally, the layer of polymer foam precursor 3 may be subjected to heat treatment, typically in an oven (not shown). In a typical embodiment, foaming of the layer of polymer foam precursor 3 results in a polymer foam layer 4, which has a greater thickness than the initial layer of polymer foam precursor 3. After processing, the first solid film 5 and / or the second solid film 6 can be removed from the polymer foam layer 4.

[0043] In an advantageous embodiment, the polymer foam precursor for use herein is an in-situ foaming composition, meaning that foaming of the precursor occurs without the need for any additional compounds, particularly external compounds.

[0044] In another advantageous embodiment, the foaming of the polymer foam precursor for use herein is carried out using a gaseous compound, in particular hydrogen gas.

[0045] In a more advantageous embodiment, the foaming of the polymer foam precursor for use herein is carried out by either gas generation or gas injection.

[0046] In a preferred embodiment, foaming of the polymer foam precursor for use herein is carried out by gas generation, particularly in-situ gas generation.

[0047] In an alternative and less advantageous embodiment, the polymer foam precursor for use herein further comprises an optional blowing agent.

[0048] The substrates used herein are not particularly limited. Suitable substrates for use herein can be readily identified by those skilled in the art in light of this disclosure.

[0049] In a typical embodiment of this disclosure, the substrate for use herein is a temporary support used for manufacturing purposes, from which a silicone rubber foam layer is separated and removed after foaming and curing. The substrate may optionally be surface-treated to enable the clean removal of the silicone rubber foam layer from the substrate (through a first solid film). Advantageously, the substrate for providing a temporary support for use herein may be provided in the form of an endless belt. Alternatively, the substrate for use herein may be a stationary (static) temporary support.

[0050] In a particular embodiment of this disclosure, the polymer foam layer obtained after foaming and curing can be separated from the substrate and, for example, wound onto a roll.

[0051] According to one advantageous aspect of this disclosure, the substrates for use herein include materials selected from the group consisting of polymers, metals, ceramics, composites, and any combination or mixture thereof.

[0052] A polymer foam layer for use in this disclosure may be obtained by a method using a coating tool having an upstream and a downstream side. The coating tool is offset from the substrate and forms a gap perpendicular to the surface of the substrate.

[0053] The coating tools used herein are not particularly limited. Any coating tool known in the art may be used in the context of this disclosure. Suitable coating tools for use herein can be readily identified by those skilled in the art in light of this disclosure.

[0054] Each coating tool useful in this disclosure has an upstream side (or upstream surface) and a downstream side (or downstream surface). In a typical embodiment, a coating tool for use herein further comprises a bottom portion facing the surface of a substrate that receives a polymer foam precursor. The gap is measured as the minimum distance between the bottom portion of the coating tool and the exposed surface of the substrate. The gap may be essentially uniform in the lateral direction (i.e., perpendicular to the downstream direction) or may vary continuously or discontinuously in the lateral direction, respectively. The gap between the coating tool and the surface of the substrate is typically adjusted to control the thickness of each coating, in conjunction with other parameters including, for example, the downstream velocity of the substrate, the type of coating tool, the angle at which the coating tool is oriented relative to the perpendicular direction of the substrate, and the type of substrate.

[0055] In one advantageous embodiment of the present disclosure, the gap formed from the substrate by the coating tool (coating tool gap) is in the range of 10 to 3000 micrometers, 50 to 2500 micrometers, 50 to 2000 micrometers, 50 to 1500 micrometers, 100 to 1500 micrometers, 100 to 1000 micrometers, 200 to 1000 micrometers, 200 to 800 micrometers, or even 200 to 600 micrometers.

[0056] The coating tools used herein can be positioned perpendicular to the surface of the substrate, or they can be tilted such that the angle between the substrate surface and the downstream side (or downstream face) of the coating tool is in the range of 50° to 130°, or even 80° to 100°. The coating tools useful in this disclosure are typically solid and may be rigid or flexible. The coating tools used herein can take on a variety of shapes, forms, and sizes depending on the intended application and expected properties of the silicone rubber foam layer.

[0057] In an advantageous embodiment, coating tools for use herein include materials selected from the group consisting of polymers, metals, composites, glass, and any combination or mixture thereof. More advantageously, coating tools for use herein include materials selected from the group consisting of metals, particularly aluminum, stainless steel, and any combination thereof. Flexible coating tools for use herein are typically relatively thin, in particular having a downstream thickness in the range of 0.1 to 0.75 mm. Rigid coating tools for use herein are usually at least 1 mm thick, or even more than 3 mm thick.

[0058] According to a typical embodiment of this disclosure, coating tools for use herein are selected from the group consisting of coating knives, coating blades, coating rolls, coating roll blades, and any combination thereof.

[0059] In an advantageous embodiment, the coating tool for use herein is selected from the group of coating knives. The use of a coating tool in the form of a coating knife has been found to provide a more reproducible coating process and a better quality coating, which is converted into a silicone rubber foam layer with advantageous properties.

[0060] In an advantageous embodiment, the coating tool for use herein is selected from the group of coating knives and air knives.

[0061] In another advantageous embodiment, the cross-sectional profile of the bottom portion of the longitudinal coating tool (particularly the coating knife) is designed so that a precursor layer is formed and excess precursor is removed. Typically, the cross-sectional profile of the bottom portion, as shown by the transversely extending edge of the coating tool facing the substrate, is essentially planar, curved, concave, or convex.

[0062] A coating tool suitable for use herein is described in concurrently pending European Patent Application No. 20160564.9 (Agent Reference Number 82970EP002, in the name of 3M Innovative Properties Company).

[0063] According to an advantageous aspect of the present disclosure, the polymer foam layer of the present disclosure is obtained by a method in which a step is performed in which a step is performed in which a step is performed in which a curable foam precursor of the polymer foam is provided upstream of a coating tool, a second solid film is provided, and the second solid film is applied along the upstream side of the coating tool, so that the first solid film and the second solid film are applied simultaneously with the formation of (adjacent) layers of the polymer foam precursor.

[0064] According to another advantageous aspect of the present disclosure, the steps of foaming or enabling foaming of a polymer foam precursor and curing or enabling curing of a layer of polymer foam precursor to form a polymer foam layer are carried out simultaneously.

[0065] The solid films used herein as the first and second solid films are not particularly limited. Any solid film known in the art may be formally used in the context of this disclosure. Suitable solid films for use herein can be readily identified by those skilled in the art in light of this disclosure.

[0066] In one advantageous embodiment, the first solid film and / or second solid film for use in the present disclosure is an impermeable film, in particular an impermeable flexible film. As used herein, the term “impermeable” is intended to mean impermeability to liquid and gaseous compounds, in particular gaseous compounds.

[0067] According to another advantageous aspect of this disclosure, the first solid film and / or second solid film for use herein is selected from the group consisting of polymer films, metal films, composite films, and any combination thereof.

[0068] In a more advantageous aspect of this disclosure, the first solid film and / or second solid film for use herein is selected from polymer films, particularly polymer films comprising polymer materials selected from the group consisting of thermoplastic polymers.

[0069] In a more advantageous embodiment of the present disclosure, the first solid film and / or second solid film for use herein is a polymer film, the polymer material being selected from the group consisting of polyester, polyether, polyolefin, polyamide, polybenzimidazole, polycarbonate, polyethersulfone, polyoxymethylene, polyetherimide, polystyrene, polyvinyl chloride, and any mixture or combination thereof.

[0070] In a more advantageous embodiment of this disclosure, the first solid film and / or second solid film for use herein is a polymer film comprising a polymer material selected from the group consisting of polyester, polyolefins (particularly PP and PE), polyetherimide, and any mixture or combination thereof.

[0071] In a particularly advantageous embodiment, the first solid film and / or second solid film for use in the present disclosure is a polymer film comprising a polymer material selected from the group consisting of polyester, particularly polyethylene terephthalate.

[0072] According to an advantageous aspect of the present disclosure, the polymer foam layer of the present disclosure is obtained by a method in which a first solid film is applied to the bottom surface of the polymer foam precursor layer and a second solid film is applied to the top (exposed) surface of the polymer foam precursor layer.

[0073] In a typical embodiment of this disclosure, the first solid film and / or the second solid film are in direct contact with the adjacent polymer foam layer.

[0074] In another advantageous embodiment of the present disclosure, the first main (top) surface and the second (opposing) main (bottom) surface of the polymer foam layer, and / or the first solid film and / or the second solid film, are free from any adhesion-promoting compositions or treatments, in particular free from priming compositions, adhesive compositions, and physical surface treatments.

[0075] In alternatively advantageous embodiments of the present disclosure, the first main (top) surface and the second (opposing) main (bottom) surface of the polymer foam layer, and / or the first solid film and / or the second solid film, include adhesion-promoting compositions or treatments, particularly priming compositions, adhesive compositions, and physical surface treatments.

[0076] In yet another advantageous embodiment of this disclosure, no intermediate layer of any kind is included between the first main (top) surface or the second (opposing) main (bottom) surface of the polymer foam layer and the first solid film and / or the second solid film.

[0077] In a typical embodiment of the present disclosure, the first and second solid films are in smooth contact with the corresponding surfaces of the silicone rubber foam layer, thereby avoiding (or at least reducing) the presence of air between the solid film and the corresponding surfaces of the polymer foam layer.

[0078] In one advantageous embodiment, the polymer foam layer for use herein comprises gas cavities, particularly gaseous hydrogen cavities, air gas cavities, and any mixture thereof.

[0079] In one advantageous embodiment, the polymer foam layer for use herein includes a gas cavity having an oblong shape in the thickness direction of the layer (i.e., in the direction perpendicular to the plane formed by the foam layer).

[0080] In a more advantageous embodiment, the gas cavities that may exist in the silicone rubber foam layer have an elongated elliptical shape in the direction of the layer thickness.

[0081] Advantageously, the gas cavities used herein are not surrounded by any ceramic or polymer shell (other than the surrounding silicone polymer matrix).

[0082] In a particular embodiment, the gas cavity for use herein has an average size (of its maximum dimensions) of 500 micrometers or less, 400 micrometers or less, 300 micrometers or less, 200 micrometers or less, 150 micrometers or less, 120 micrometers or less, 100 micrometers or less, 80 micrometers or less, 60 micrometers or less, 50 micrometers or less, 40 micrometers or less, 30 micrometers or less, or even greater than 20 micrometers (calculated from SEM micrographs).

[0083] In another specific embodiment, gas cavities for use herein have an average size (of maximum dimensions) of 5–3000 micrometers, 5–2000 micrometers, 10–1500 micrometers, 20–1500 micrometers, 20–1000 micrometers, 20–800 micrometers, 20–600 micrometers, 20–500 micrometers, or even 20–400 micrometers (calculated from SEM micrographs).

[0084] In a typical embodiment, the polymer foam layer for use herein does not contain hollow cavities (surrounded by any ceramic or polymer shell) selected from the group consisting of hollow microspheres, glass bubbles, expandable microspheres, particularly hydrocarbon-filled expandable microspheres, hollow inorganic particles, expandable inorganic particles, and any combination or mixture thereof.

[0085] In a favorable embodiment, the polymer foam layer for use herein comprises a non-syntactic foam.

[0086] The polymer foam layer used herein may contain additional (optional) components or additives, depending on the intended application.

[0087] In certain aspects of this disclosure, polymer foam layers for use herein further include additives particularly selected from the group consisting of flame retardants, softeners, curing agents, filler materials, tackifiers, nucleating agents, colorants, pigments, maintenance agents, rheology modifiers (in particular aluminum hydroxide, magnesium hydroxide, magnesium carbonate, hanthite, hydromagnesite, hanthite-hydromagnesite, neskehonite, and calcium carbonate), UV stabilizers, thixotropes, surface additives, flow additives, nanoparticles, antioxidants, strengthening agents, toughening agents, silica particles, glass or synthetic fibers, thermal insulating particles, conductive particles, electrical insulating particles, infrared shielding particles, and any combination or mixture thereof.

[0088] In one beneficial embodiment, the polymer foam layer further comprises a non-combustible (or non-flammable) filler material. In a more beneficial embodiment, the non-combustible filler material for use herein is selected from the group of inorganic fibers, particularly from the group consisting of mineral fibers, mineral wool, silicate fibers, ceramic fibers, glass fibers, carbon fibers, graphite fibers, asbestos fibers, aramid fibers, and any combination or mixture thereof.

[0089] In a more advantageous embodiment, the non-combustible filler material for use herein is selected from the group consisting of mineral fibers, silicate fibers, ceramic fibers, asbestos fibers, aramid fibers, and any combination or mixture thereof.

[0090] In a particularly beneficial embodiment, the non-flammable filler material for use herein is selected from the group consisting of mineral fibers. Surprisingly, in the context of this disclosure, polymer foams (particularly silicone rubber foams) further containing mineral fibers have been found to provide excellent heat resistance and thermal stability, as well as improved resistance to surface cracking and surface brittleness, even after prolonged exposure to temperatures up to 600°C. Though not bound by theory, these beneficial features are thought to be due in particular to the excellent compatibility between the surrounding polymer matrix (particularly silicone polymer matrix) and the mineral fibers (particularly silicate fibers), which is involved in densifying and mechanically stabilizing the resulting matrix.

[0091] In a particular embodiment of this implementation, the non-flammable filler material for use herein is included in the polymer foam in an amount ranging from 0.5 to 40% by weight, 1 to 30% by weight, 1 to 20% by weight, 1 to 10% by weight, 1 to 8% by weight, 2 to 8% by weight, 2 to 6% by weight, or even 3 to 6% by weight, based on the total weight of the polymer foam precursor composition.

[0092] In another typical embodiment, the polymer foam layer for use herein does not contain a thermally conductive filler.

[0093] According to an advantageous aspect of the present disclosure, the neat polymer foam layer for use herein has 500 kg / m 3 or less, 450 kg / m 3 or less, 400 kg / m 3 or less, 380 kg / m 3 or less, 350 kg / m 3 or less, 320 kg / m 3 or less, 300 kg / m 3 or less, 280 kg / m 3 or less, 250 kg / m 3 or less, 220 kg / m 3 or less, or even 200 kg / m 3 or less when measured according to the method described in the experimental section.

[0094] According to another advantageous aspect of the present disclosure, the neat polymer foam layer for use herein is 200 to 500 kg / m when measured according to the method described in the experimental section 3 , 200 to 450 kg / m 3 , 200 to 400 kg / m 3 , 200 to 380 kg / m 3 , 200 to 350 kg / m 3 , 200 to 320 kg / m 3 , 200 to 300 kg / m 3 , 200 to 280 kg / m 3 , or even 200 to 250 kg / m 3 having a density within the range of.

[0095] According to yet another advantageous aspect of the present disclosure, the neat polymer foam layer for use herein has a hardness (Shore 00) of greater than 10, greater than 15, greater than 20, greater than 25, greater than 30, greater than 40, or even greater than 50.

[0096] According to yet another advantageous aspect of the present disclosure, the neat polymer foam layer for use herein has a hardness (Shore 00) in the range of 10 to 80, 10 to 70, 20 to 70, 25 to 60, 25 to 55, 30 to 55, 30 to 50, 30 to 45, or even 30 to 40.

[0097] According to yet another advantageous aspect of this disclosure, a neat polymer foam layer for use herein has a heat transfer time up to 150°C of more than 20 seconds, more than 40 seconds, more than 60 seconds, more than 80 seconds, more than 100 seconds, more than 120 seconds, more than 140 seconds, more than 150 seconds, more than 160 seconds, more than 170 seconds, or even more than 180 seconds, as measured according to the heat insulation test method 1 described in the experimental section.

[0098] According to yet another advantageous aspect of this disclosure, a neat polymer foam layer for use herein has a heat transfer time up to 150°C, measured according to the heat insulation test method 1 described in the experimental section, ranging from 20 to 200 seconds, 40 to 200 seconds, 60 to 200 seconds, 100 to 200 seconds, 120 to 200 seconds, 140 to 200 seconds, 160 to 200 seconds, or even 160 to 180 seconds.

[0099] According to yet another advantageous aspect of this disclosure, a neat polymer foam layer for use herein has a thermal conductivity of 1 W / m·K or less, 0.8 W / m·K or less, 0.6 W / m·K or less, 0.5 W / m·K or less, 0.4 W / m·K or less, 0.3 W / m·K or less, 0.2 W / m·K or less, 0.1 W / m·K or less, 0.05 W / m·K or less, or even 0.01 W / m·K or less, as measured according to the test methods described in the Experimental Section.

[0100] According to yet another advantageous aspect of this disclosure, neat polymer foam layers for use herein have a thermal conductivity in the range of 0.01–1 W / m·K, 0.05–1 W / m·K, 0.1–1 W / m·K, 0.2–1 W / m·K, or even 0.2–0.8 W / m·K when measured according to the test methods described in the Experimental Section.

[0101] According to yet another advantageous aspect of this disclosure, a neat polymer foam layer for use herein undergoes a ceramicization process at a temperature of 600°C or less, 550°C or less, 500°C or less, 450°C or less, 400°C or less, 350°C or less, 300°C or less, or even 250°C or less.

[0102] According to yet another advantageous aspect of this disclosure, a neat polymer foam layer for use herein undergoes a ceramicization process at a temperature in the range of 200°C to 600°C, 200°C to 550°C, 200°C to 500°C, 200°C to 450°C, 200°C to 400°C, 200°C to 350°C, 250°C to 350°C, or even 250°C to 300°C.

[0103] In the context of this disclosure, it has been found, quite surprisingly, that polymer foam layers capable of undergoing a ceramicization process, particularly at relatively low temperatures, result in excellent heat resistance and thermal stability properties.

[0104] According to yet another advantageous aspect of this disclosure, the neat polymer foam layer for use herein has a V-0 classification when measured according to the UL-94 standard flammability test method.

[0105] In one advantageous embodiment, the neat polymer foam layer for use herein has a thickness of 10,000 micrometers or less, 8,000 micrometers or less, 6,000 micrometers or less, 5,000 micrometers or less, 4,000 micrometers or less, 3,000 micrometers or less, 2,500 micrometers or less, 2,000 micrometers or less, or even 1,500 micrometers or less.

[0106] In another advantageous aspect, neat polymer foam layers for use herein have thicknesses ranging from 100 to 10000 micrometers, 100 to 8000 micrometers, 100 to 6000 micrometers, 200 to 5000 micrometers, 300 to 5000 micrometers, 300 to 4500 micrometers, 300 to 4000 micrometers, 500 to 4000 micrometers, 500 to 3000 micrometers, 500 to 2500 micrometers, 500 to 2000 micrometers, 500 to 1500 micrometers, 800 to 1500 micrometers, or even 1000 to 1500 micrometers.

[0107] According to a particular aspect of this disclosure, the polymer foam layer for use herein may comprise a first solid film and / or a second solid film. In an alternative implementation, the polymer foam layer may not comprise either the first solid film or the second solid film.

[0108] As will be apparent to those skilled in the art, the polymer foam layers for use herein may take on a variety of forms, shapes, and sizes depending on the intended application. Similarly, the polymer foam layers for use herein may be post-processed or transformed as is customary practice in the art.

[0109] In one exemplary embodiment, the polymer foam layer for use herein may take the form of a roll wound around a core, particularly a horizontally wound roll. The polymer foam layer in the wound roll may or may not comprise a first solid film and / or a second solid film.

[0110] According to one exemplary embodiment, the polymer foam layer for use herein can be cut into smaller pieces of various forms, shapes, and sizes.

[0111] The buffer article of the present disclosure further comprises a plurality of spacer elements disposed within a polymer foam layer, each spacer element being at least partially embedded within the polymer foam layer, and each spacer element having a size greater than 200 micrometers (its maximum dimension).

[0112] Spacer elements for use herein are not particularly limited, as long as they have a maximum size exceeding 200 micrometers. Suitable spacer elements for use herein can be readily identified by those skilled in the art in light of this disclosure.

[0113] According to one advantageous aspect of the present invention, the two opposing end portions of each spacer element are completely embedded within the polymer foam layer.

[0114] According to another advantageous aspect of this disclosure, the spacer element for use herein is a high-density (particulate) element.

[0115] In another advantageous embodiment, the spacer element for use herein is a non-hollow (solid) element.

[0116] In yet another advantageous embodiment, the spacer element for use herein is non-porous.

[0117] In one useful embodiment of the cushioning article, the spacer elements for use herein are uniformly (or homogeneously) arranged within the polymer foam layer along a plane formed by the polymer foam layer.

[0118] In a particular embodiment, the spacer elements for use herein are arranged within the polymer foam layer uniformly (or homogeneously) parallel to the plane formed by the polymer foam layer.

[0119] In another useful embodiment of the buffer article, the multiple spacer elements for use herein are uniformly (or homogeneously) arranged within the polymer foam layer along the thickness of the polymer foam layer.

[0120] In another alternatively beneficial embodiment, multiple spacer elements are randomly arranged within the polymer foam layer along a plane formed by the polymer foam layer.

[0121] In another alternatively advantageous embodiment, multiple spacer elements are randomly arranged within the polymer foam layer along the thickness of the polymer foam layer.

[0122] In a more advantageous embodiment, the spacer elements are arranged at equal intervals from one another within the polymer foam layer, particularly along the plane formed by the polymer foam layer.

[0123] According to an alternative embodiment of the present disclosure, the spacer elements are arranged at random intervals from one another within the polymer foam layer, particularly along the plane formed by the polymer foam layer.

[0124] According to a typical embodiment of the buffer article of this disclosure, each spacer element for use herein has an entire outer surface, and at least a portion of the entire outer surface of each spacer element is embedded in a polymer foam layer.

[0125] In a useful embodiment, a plurality of spacer elements for use herein are arranged within a polymer foam layer such that 10-100%, 30-100%, 50-100%, 70-100%, 90-100%, 95-100%, or even 100% of the entire outer surface of each spacer element is embedded within the polymer foam layer.

[0126] According to a particularly advantageous aspect of this disclosure, the multiple spacer elements are completely embedded within the polymer foam layer.

[0127] In one exemplary embodiment, each spacer element for use herein has a size (of its maximum dimension) of more than 250 micrometers, more than 300 micrometers, more than 350 micrometers, more than 400 micrometers, more than 450 micrometers, more than 500 micrometers, more than 600 micrometers, more than 700 micrometers, more than 800 micrometers, more than 1000 micrometers, more than 1500 micrometers, more than 2000 micrometers, more than 2500 micrometers, more than 3000 micrometers, more than 3500 micrometers, or even more than 4000 micrometers.

[0128] In one advantageous embodiment, each spacer element for use herein has a size (maximum dimension) in the range of 250-6000 micrometers, 300-6000 micrometers, 400-6000 micrometers, 500-6000 micrometers, 550-6000 micrometers, 600-5500 micrometers, 600-5000 micrometers, 800-5000 micrometers, 800-4500 micrometers, or even 800-4000 micrometers.

[0129] In a more advantageous aspect of this disclosure, each spacer element for use herein has an aspect ratio AR(ratio x / y), where x is the length of the maximum dimension of the spacer element and y is the length of the minimum dimension of the spacer element, and the aspect ratio of each spacer element is 5 or less, 4 or less, 3 or less, 2 or less, or even 1 or less.

[0130] According to another advantageous aspect of this disclosure, the spacer elements for use herein have a uniform shape and / or size.

[0131] According to another alternatively advantageous aspect of this disclosure, the spacer elements for use herein have non-uniform shapes and / or sizes.

[0132] According to yet another alternatively advantageous aspect of this disclosure, each spacer element for use herein has a regular or irregular shape.

[0133] In one exemplary aspect of the present disclosure, each spacer element for use herein has an overall shape (as seen from a top view) selected from the group consisting of circular, semicircular, elliptical, square, triangular, rectangular, rhombus, polygonal, linear stripe, nonlinear stripe, curved stripe, and any combination thereof.

[0134] In another exemplary embodiment, each spacer element for use herein has an overall shape (as seen from a side section view) selected from the group consisting of cylindrical, pyramidal, conical, spherical, hemispherical, barrel-shaped, rod-shaped, stick-shaped, bar-shaped, pole-shaped, and any combination thereof.

[0135] Exemplary spacer elements for use in this specification are schematically shown in Figures 3 to 5, which are side cross-sectional views of an exemplary buffer article 14 according to an exemplary embodiment of the present disclosure. In Figures 3 to 5, spacer elements 13 of various shapes, sizes, and arrangements are shown fully embedded in a polymer foam layer 4.

[0136] In another exemplary aspect of the present disclosure, the multiple spacer elements form a patterned structure (or pattern) on a polymer foam layer (as viewed from a top view of the article), and the multiple (separate) spacer elements are not interconnected in particular.

[0137] In yet another exemplary embodiment of the present disclosure, the multiple spacer elements form a patterned structure (or pattern) on a polymer foam layer (as viewed from a top view of the article), and the multiple (separate) spacer elements are interconnected in particular.

[0138] In one beneficial embodiment, the multiple spacer elements form a patterned structure (or pattern) selected from the group consisting of grid patterns, square patterns, diamond patterns, honeycomb patterns, patterns including parallel straight or wavy lines, checkerboard patterns, brick patterns, and any combination thereof.

[0139] Exemplary patterns formed by spacer elements for use herein are schematically shown in Figures 6 and 7, which are cross-sectional top views of exemplary cushioning articles according to exemplary embodiments of the present disclosure, in which the spacer elements form different patterns along a plane formed by a polymer foam layer. In Figure 6, the multiple spacer elements form a rectangular pattern, and in Figure 7, the multiple spacer elements form a rhomboid pattern.

[0140] According to one advantage of the present disclosure, each spacer element for use herein has an overall shape (as seen from a side cross-sectional view of an article) selected from the group consisting of spherical, cylindrical, barrel, rod, stick, bar, pole, pyramidal, conical, and any combination thereof.

[0141] A further advantage of this disclosure is that each spacer element for use herein has an overall shape (as viewed from a side cross-sectional view of the article) selected from the group consisting of spherical and cylindrical shapes.

[0142] According to another advantage of the present disclosure, each spacer element for use herein has an overall shape (as viewed from a side section of the article) selected to be spherical, and the average diameter of each spherical spacer element is in the range of 250–6000 micrometers, 300–6000 micrometers, 400–6000 micrometers, 500–6000 micrometers, 500–5000 micrometers, 500–4000 micrometers, 550–3500 micrometers, 550–3000 micrometers, 550–2500 micrometers, or even 600–2000 micrometers.

[0143] According to yet another advantage of the present disclosure, each spacer element has an overall shape (as viewed from a side cross-section of the article) selected to be cylindrical, and the average diameter of each cylindrical spacer element is in the range of 250–5000 micrometers, 300–5000 micrometers, 400–5000 micrometers, 500–5000 micrometers, 500–4000 micrometers, 600–3500 micrometers, 800–3000 micrometers, 800–2500 micrometers, or even 800–2000 micrometers.

[0144] According to yet another advantage of the present disclosure, each spacer element for use herein has an overall shape (as viewed from a side section of the article) selected to be cylindrical, and the average height of each cylindrical spacer element is in the range of 250–5000 micrometers, 300–4500 micrometers, 400–4500 micrometers, 500–4500 micrometers, 800–4500 micrometers, 800–4000 micrometers, 1000–4000 micrometers, 1200–4000 micrometers, or even 1500–4000 micrometers.

[0145] According to yet another advantage of this disclosure, the ratio of the size of each spacer element (its maximum dimension) to the thickness of the polymer foam layer is in the range of 0.1–0.9, 0.1–0.8, 0.2–0.7, 0.2–0.6, or even 0.3–0.6.

[0146] In the context of this disclosure, it has been found that, surprisingly, by changing the shape, size, and arrangement of spacer elements within a polymer foam layer, different compression properties can be achieved for the corresponding buffer articles, which then translate into different thermal insulation properties and thermal runaway barrier performance. This property provides excellent structural and design flexibility for the buffer articles, which leads to a remarkable ability to fine-tune the compression properties of the buffer articles to specific applications, operating conditions, and battery cell types. The main factors influencing the compression properties of the buffer articles have been found to include the shape, size, and arrangement of spacer elements within the polymer foam layer, particularly the distance between spacer elements, the height of individual spacer elements, the specific patterns formed by multiple spacer elements within the polymer foam layer, the degree and amount of embedding of spacer elements within the polymer foam layer, and the material used to form the spacer elements.

[0147] In exemplary embodiments, the spacer element includes (or is made from) a material selected from the group consisting of elastomers, siliceous materials, ceramics, metals, thermoplastics, thermoplastic elastomers, thermoplastic non-elastomers, thermosetting materials, and any combination or mixture thereof.

[0148] In one advantageous embodiment, spacer elements for use herein include (or are made from) materials selected from the group consisting of silicone elastomers, silicon dioxide (glass), ceramics, fluorosilicone rubber, polyaramids, aromatic polyamides, polybenzimidazoles, polysulfides, polyimides, polysulfones, polyetherketones, fluorocarbons, polyisoprene, polybutadiene, polychloroprene, polyurethanes, polyolefins (PE, PP, EVA), polystyrene, and any combination or mixture thereof.

[0149] In a more advantageous embodiment, the spacer element for use herein includes (or is made from) a material selected from the group consisting of elastomer materials.

[0150] In another, more advantageous embodiment, the spacer element for use herein includes a material selected from the group consisting of silicone elastomers, particularly silicone rubber, and more specifically organopolysiloxane polymers.

[0151] In one particularly advantageous aspect of this disclosure, the spacer element for use herein includes silicone rubber.

[0152] In another, more advantageous embodiment, the spacer elements for use herein include (or are made from) a material selected from the group consisting of siliceous materials, particularly glass.

[0153] In another particularly advantageous aspect of this disclosure, the spacer elements for use herein are selected from the group consisting of (solid) glass bubbles, glass beads, and glass spheres.

[0154] In one advantageous embodiment, the spacer elements for use herein are not (elastically) deformable (or compressible) when exposed to physical force (or pressure). Surprisingly, in the context of this disclosure, it has been found that using spacer elements that are not deformable (or compressible) when exposed to physical force (or pressure) makes it possible to improve the control of the compressibility of the buffer article by introducing a compressibility limit, which in turn improves the thermal insulation properties and thermal runaway barrier performance.

[0155] In another advantageous embodiment, the spacer elements for use herein are at least partially (elastically) deformable (or compressible) when exposed to physical force (or pressure). Surprisingly, in the context of this disclosure, it has been found that using spacer elements that are deformable (or compressible) when exposed to physical force (or pressure) makes it possible to improve the customization of the compressibility of the cushioning article by introducing further compression adjustment elements. The use of deformable spacer elements allows for a more gradual deployment of compressive forces within the polymer foam layer, which makes this type of spacer element more suitable for articles requiring higher cushioning properties. The use of compressible spacer elements makes it possible to form thinner cushioning articles, in particular cushioning articles having thinner polymer foam layers.

[0156] In certain aspects of this disclosure, spacer elements for use herein further include additives particularly selected from the group consisting of flame retardants, softeners, curing agents, filler materials, tackifiers, nucleating agents, colorants, pigments, maintenance agents, rheology modifiers (in particular aluminum hydroxide, magnesium hydroxide, magnesium carbonate, hanthite, hydromagnesite, hanthite-hydromagnesite, neskehonite, and calcium carbonate), UV stabilizers, thixotropes, surface additives, flow additives, nanoparticles, antioxidants, reinforcing agents, toughening agents, silica particles, glass or synthetic fibers, thermal insulating particles, conductive particles, electrical insulating particles, infrared shielding particles, and any combination or mixture thereof.

[0157] In one beneficial embodiment, the spacer element for use herein further comprises a non-combustible (or non-flammable) filler material. In a more beneficial embodiment, the non-combustible filler material for use herein is selected from the group of inorganic fibers, in particular from the group consisting of mineral fibers, mineral wool, silicate fibers, ceramic fibers, glass fibers, carbon fibers, graphite fibers, asbestos fibers, aramid fibers, and any combination or mixture thereof.

[0158] In one particular embodiment, the spacer element further comprises a surface treatment or surface coating, the surface treatment being selected from the group consisting of hydrophilic and hydrophobic surface treatments, and more specifically, supported by silane groups.

[0159] In a typical embodiment, the cushioning article of the present disclosure is a cushioning article suitable for cushioning at least one expanding (and / or contracting) surface.

[0160] These expanding and / or contracting surfaces can typically be found in rechargeable electrical energy storage systems, particularly battery modules, and more specifically along the sidewalls of battery cells.

[0161] In a particular aspect of this disclosure, at least one expanding and / or contracting surface expands (and / or contracts) when exposed to thermal energy (heat).

[0162] In one advantageous embodiment, the buffer article of the present disclosure has a heat transfer time to 150°C of more than 20 seconds, more than 60 seconds, more than 100 seconds, more than 150 seconds, more than 180 seconds, more than 200 seconds, more than 240 seconds, more than 280 seconds, more than 300 seconds, more than 320 seconds, more than 340 seconds, more than 350 seconds, or even more than 360 seconds, when measured at 0.1 MPa according to the thermal insulation test method 2 described in the experimental section.

[0163] According to yet another advantageous aspect of this disclosure, the buffer article has a heat transfer time up to 150°C, measured at 0.1 MPa according to Test Method 2 described in the Experimental Section, in the range of 20-380 seconds, 40-380 seconds, 60-380 seconds, 100-380 seconds, 150-380 seconds, 180-380 seconds, 200-380 seconds, 250-380 seconds, or even 300-380 seconds.

[0164] According to yet another advantageous aspect of this disclosure, the buffer article has a heat transfer time up to 150°C of more than 20 seconds, more than 40 seconds, more than 60 seconds, more than 80 seconds, more than 100 seconds, more than 120 seconds, more than 140 seconds, or even more than 150 seconds, when measured at 1 MPa according to the thermal insulation test method 2 described in the experimental section.

[0165] In yet another advantageous embodiment, the buffer articles of this disclosure have a heat transfer time up to 150°C, in the range of 20-180 seconds, 40-180 seconds, 60-180 seconds, 100-180 seconds, 120-180 seconds, 140-180 seconds, or even 140-160 seconds, when measured at 1 MPa according to the thermal insulation test method 2 described in the experimental section.

[0166] In yet another advantageous embodiment, the buffer articles of this disclosure have a thermal conductivity of 1 W / m·K or less, 0.8 W / m·K or less, 0.6 W / m·K or less, 0.5 W / m·K or less, 0.4 W / m·K or less, 0.3 W / m·K or less, 0.2 W / m·K or less, 0.1 W / m·K or less, 0.05 W / m·K or less, or even 0.01 W / m·K or less, as measured according to the test methods described in the Experimental Section.

[0167] In yet another advantageous embodiment, the buffer articles of this disclosure have a thermal conductivity in the range of 0.01 to 1 W / m·K, 0.05 to 1 W / m·K, 0.1 to 1 W / m·K, 0.2 to 1 W / m·K, or even 0.2 to 0.8 W / m·K when measured according to the test methods described in the Experimental Section.

[0168] In yet another advantageous embodiment, the buffer article of this disclosure has a V-0 classification when measured according to the UL-94 standard flammability test method.

[0169] According to exemplary embodiments of the present disclosure, the cushioning article has a thickness in the range of 100 to 20,000 micrometers, 100 to 15,000 micrometers, 100 to 10,000 micrometers, 100 to 8,000 micrometers, 100 to 6,000 micrometers, 200 to 5,000 micrometers, 300 to 5,000 micrometers, 300 to 4,500 micrometers, 300 to 4,000 micrometers, 500 to 4,000 micrometers, 1,000 to 3,000 micrometers, 1,000 to 2,500 micrometers, 1,500 to 2,500 micrometers, or even 2,000 to 2,500 micrometers.

[0170] In another aspect, the present disclosure relates to a method for manufacturing the above-described buffer article, wherein the method is a) A step of providing the polymer foam layer described above, b) A step of providing the above-mentioned multiple spacer elements, c) The process includes incorporating multiple spacer elements into a polymer foam layer so that the multiple spacer elements are arranged within the polymer foam layer and each spacer element is at least partially embedded within the polymer foam layer.

[0171] In one advantageous embodiment, the method includes the steps of creating perforations in a polymer foam layer and incorporating a plurality of spacer elements into the perforations in the polymer foam layer.

[0172] In another advantageous embodiment, the method includes the step of incorporating a (curable) precursor of a spacer element into the perforations of a polymer foam layer.

[0173] In yet another aspect, the present disclosure relates to a method for manufacturing the above-described buffer article, wherein the method is a) A step of providing a substrate, b) A step of providing a solid film and applying it onto a substrate, c) A step of providing a coating tool comprising an upstream side and a downstream side, which is offset from the substrate and forms a gap perpendicular to the surface of the substrate, d) A step of moving the solid film downstream with respect to the coating tool, e) A step of providing a curable (and foamable) polymer foam precursor upstream of a coating tool, thereby coating the polymer foam precursor as a layer through gaps onto a substrate having a solid film, f) A step of providing the above-mentioned multiple spacer elements, g) A step of incorporating multiple spacer elements into a polymer foam precursor so that the multiple spacer elements are positioned within the polymer foam precursor and each spacer element is at least partially embedded within the polymer foam precursor, h) A step of foaming or enabling foaming of a polymer foam precursor, i) A step of curing or enabling curing of a polymer foam precursor layer to form a polymer foam layer, j) A step of optionally subjecting a polymer foam precursor layer to heat treatment, k) optionally includes the step of removing a solid film from the polymer foam layer.

[0174] In one advantageous aspect of this method, the step of incorporating multiple spacer elements into a polymer foam precursor is performed by pressing the multiple spacer elements into the polymer foam precursor, particularly using a coating tool.

[0175] In another advantageous aspect of this method, the multiple spacer elements are provided upstream of the coating tool, particularly on a substrate on which a solid film is provided.

[0176] In yet another advantageous embodiment of this method, the multiple spacer elements are provided along the upstream side of the coating tool so that the solid film and the multiple spacer elements are applied and incorporated simultaneously with the formation of (adjacent) layers of the polymer foam precursor.

[0177] In yet another advantageous embodiment of this method, immediately after the step of providing a curable (and foamable) precursor of a polymer foam upstream of a coating tool is performed, a second solid film is provided and the second solid film is applied along the upstream side of the coating tool so that the first and second solid films are applied simultaneously with the formation of (adjacent) layers of the polymer foam precursor.

[0178] A schematic diagram of this exemplary method for manufacturing cushioning articles and an exemplary coating apparatus is shown in Figure 2. The exemplary coating apparatus for use in this method is very similar to the coating apparatus 1 described in Figure 1, except that it uses a rotary coating tool 7.

[0179] In a typical embodiment of this exemplary method, a curable foam precursor 3 of a polymer foam is provided upstream of a coating tool 7, thereby coating the polymer foam precursor 3 as a layer through gaps onto a substrate 2 having a first solid film 5. A second solid film 6 is applied (at least partially) along the upstream side of the coating tool 7, and the first solid film 5 and the second solid film 6 are applied simultaneously with the formation of the layers of polymer foam precursor 3. Multiple spacer elements 13 are provided on the substrate 2 having the first solid film 5, in an upstream position relative to both the coating tool 7 and the polymer foam precursor 3. The multiple spacer elements 13 are provided along the upstream side of the coating tool 7, and are applied and incorporated simultaneously with the formation of the (adjacent) layers of polymer foam precursor 3, along with the solid film 5 and the multiple spacer elements 13.

[0180] The polymer foam precursor 3 layer is then foamed and cured to yield a polymer foam layer 4, which typically has a first solid film 5 on its bottom surface and a second solid film 6 on its top surface, with multiple spacer elements 13 incorporated within the polymer foam layer 4. Optionally, the polymer foam precursor 3 layer may be subjected to heat treatment, typically in an oven (not shown). After processing, the first solid film 5 and / or the second solid film 6 can be removed from the polymer foam layer 4, thereby providing a buffer article 14.

[0181] In another advantageous aspect of this method, the coating tool (outer surface) is provided with a material that is at least partially (elastically) deformable (or compressible) when exposed to a physical force (pressure).

[0182] In another advantageous embodiment of this method, the substrate or solid film (outer surface) is provided with a material that is at least partially (elastically) deformable (or compressible) when exposed to a physical force (pressure).

[0183] In yet another advantageous embodiment of this method, the multiple spacer elements are incorporated into the polymer foam precursor (during or after) the formation of the polymer foam precursor layer, particularly before the step of curing or enabling the curing of the polymer foam precursor layer.

[0184] In yet another advantageous embodiment of this method, the multiple spacer elements are incorporated into the polymer foam precursor (during or after) the formation of the polymer foam precursor layer, particularly after a step of curing or enabling the curing of the polymer foam precursor layer.

[0185] In one advantageous embodiment of this method, the step of providing a curable (foaming) precursor of a polymer foam upstream of the coating tool is performed immediately before the step of providing a spacer layer or solid film and applying it along the upstream side of the coating tool.

[0186] According to another advantageous embodiment of this method, the steps of foaming or enabling foaming of a polymer foam precursor and curing or enabling curing of a layer of polymer foam precursor to form a polymer foam layer are carried out simultaneously.

[0187] In another aspect, the disclosure covers thermal barrier articles including the aforementioned buffer articles.

[0188] In yet another aspect, the disclosure relates to a rechargeable electrical energy storage system, in particular to a battery module comprising the aforementioned thermal (runaway) barrier article.

[0189] In yet another embodiment, the present disclosure relates to a battery module comprising a plurality of battery cells separated from each other by gaps, and the above-mentioned buffer foam layers disposed in the gaps between the battery cells.

[0190] Figure 8 shows an exemplary assembled battery module 15 according to one aspect of the present disclosure, which comprises a plurality of battery cells 16 separated from each other by gaps, and a plurality of buffer articles 14 placed in the gaps between the battery cells 16. The battery module is further provided with a base plate 18 on which a thermally conductive gap filler 17 is arranged.

[0191] Suitable battery modules, battery subunits, and methods for manufacturing the same for use herein are described, for example, in European Patent No. 3352290(A1) (Goeb et al.), particularly in Figures 1 to 3 and paragraphs

[0016] to

[0035] , the contents of which are fully incorporated herein by reference.

[0192] According to an advantageous embodiment of the battery module described herein, the battery cells for use herein are selected from the group consisting of pouch-type energy storage cells and prism-type energy storage cells, and in particular from the group consisting of pouch-type energy storage cells.

[0193] In another aspect, the present disclosure relates to a method for manufacturing a battery module, a) A step of providing multiple battery cells separated from each other by gaps, b) A method comprising the step of placing the aforementioned buffering articles in the gaps between battery cells.

[0194] In yet another embodiment, the disclosure relates to a method for buffering at least one expanding (and / or contracting) surface, comprising the step of applying the buffering article described above to at least a portion of the at least one expanding (and / or contracting) surface. In one particular embodiment, the at least one expanding and / or contracting surface expands (and / or contracts) when exposed to thermal energy (heat).

[0195] In yet another aspect, the disclosure relates to the use of the above-mentioned cushioning articles for industrial applications, particularly for thermal management applications, more specifically in the transportation industry, and more specifically in the automotive, aviation, and aerospace industries.

[0196] In yet another aspect, this disclosure relates to the use of the aforementioned buffer articles as thermal barriers, particularly as thermal runaway barriers.

[0197] In yet another embodiment, the disclosure relates to the use of the above-mentioned buffer articles as thermal barriers, particularly thermal runaway barriers, in rechargeable electrical energy storage systems, particularly in battery modules.

[0198] In yet another embodiment, the disclosure relates to the use of the aforementioned buffer articles as thermal barrier spacers between multiple battery cells present in a rechargeable electrical energy storage system, particularly a battery module, and especially as thermal runaway barrier spacers.

[0199] In yet another embodiment, the disclosure relates to the use of the aforementioned buffer articles as thermal buffer spacers between multiple battery cells present in a rechargeable electrical energy storage system, particularly a battery module.

[0200] In yet another aspect, the disclosure relates to the use of the above-described buffer article as a buffer spacer for buffering at least one expanding (and / or contracting) surface, wherein the at least one expanding surface expands (and / or contracts) particularly when exposed to thermal energy (heat). [Examples]

[0201] The present disclosure will be further illustrated by the following embodiments. These embodiments are for illustrative purposes only and are not intended to limit the scope of the appended claims.

[0202] Test method 1) Thermal stability test This test was conducted in a muffle furnace at 600°C. The test specimen was cut from the sample sheet and placed in a porcelain crucible. The crucible was then placed in the furnace at 600°C for 3 minutes, removed, allowed to cool, and analyzed by microscopic examination. The weight loss (%) of the sample after 3 minutes at 600°C was calculated.

[0203] 2) Thermal insulation test 1 This test was performed in compression mode using a Zwick tensile / compression testing machine. The compression testing machine had two plates (dimensions: 65 × 80 × 20 mm W × L × H, made of Inconel® steel, with an insulated exterior): a low-temperature (23°C) bottom plate equipped with a thermocouple for temperature recording, and an upper plate heated to a constant temperature of 600°C. At the start of the test, a heat shield was placed between the two plates. The sample was placed on the low-temperature bottom plate and the heat shield was removed. The upper plate was moved to a 1000 micrometer gap between the two plates. The temperature rise of the low-temperature plate was recorded over time. Specifically, the time in seconds for the low-temperature plate to reach 150°C was recorded.

[0204] 3) Thermal insulation test 2 This test was performed in compression mode using a Zwick tensile / compression testing machine. The compression testing machine had two plates (dimensions: 65 × 80 × 20 mm W × L × H, made of Inconel® steel, with an insulated exterior): a low-temperature (23°C) bottom plate equipped with a thermocouple for temperature recording, and an upper plate heated to a constant temperature of 600°C. At the start of the test, a heat shield was placed between the two plates. The sample was placed on the low-temperature bottom plate, and the heat shield was removed. The upper plate was moved toward the bottom plate until a specific resisting pressure or compressive force (0.1 MPa or 1 MPa) was reached. The pressure was maintained over the measurement time. The temperature rise of the cooling plate was then recorded over time. Specifically, the time in seconds for the low-temperature plate to reach 150°C was recorded.

[0205] 4) Measurement of thermal conductivity The thermal conductivity of the cured composition was measured using flash analysis with a Netzsch Hyperflash LFA467 (Netzsch, Selb, Germany) according to ASTM E1461 / DIN EN821 (2013). A 1 mm thick sample was prepared by coating the curable composition between two PET release liners with a knife coater and curing it at room temperature. The sample was then carefully cut into a 10 mm × 10 mm square using a knife cutter and fitted into a sample holder. Before measurement, both sides of the sample were coated with a thin layer of graphite (GRAPHIT33, Kontakt Chemie). For the measurement, a pulse of light (xenon flash lamp, 230 V, duration 20-30 microseconds) was irradiated to the bottom of the sample, and the temperature of the top of the sample was measured with an InSb IR detector. The diffusivity was then calculated from the thermogram fitting using the Cowan method. Three measurements were performed for each sample at 23°C. For each formulation, three samples were prepared and measured. Thermal conductivity was calculated from the thermal diffusivity, density, and specific heat capacity of each sample. Heat capacity (Cp) was calculated in joules per gram per Kelvin using a Netzsch-LFA Hyper Flash in combination with a standard sample (Polyceram). Density (d) was measured in grams per cubic centimeter based on the weight and geometric dimensions of the sample. Using these parameters, thermal conductivity (L) was calculated in watts per meter per Kelvin according to L = a·d·Cp.

[0206] 5) Flammability test The tests were conducted using the UL94 standard, which is a standard for safety testing of the flammability of plastic materials for apparatus and equipment components. The UL94 standard is a plastic flammability standard published by Underwriters Laboratories in the United States. This standard determines whether the material tends to extinguish or spread the flame when the test specimen is ignited. The UL94 standard is consistent with IEC 60707, 60695-11-10 and 60695-11-20 and ISO 9772 and 9773. A 75mm x 150mm sample was exposed to a 2cm, 50W tickrrel burner flame ignition source. The test specimen was placed vertically above the flame with the test flame touching the bottom of the specimen. For each specimen, the time to extinguishment was measured and assigned a V grade. As shown in Table 1 below, Grade V is a measure of the time it takes for the sample to extinguish without burning up to the top of the clamp or dropping molten material that would ignite the cotton indicator. [Table 1]

[0207] 6) Compression test The compression test was performed in compression mode using a Zwick tensile testing machine. The sample had a diameter of 50.8 mm and a thickness of over 1000 micrometers. The test was conducted at 23°C. The upper plate of the compression testing machine was moved at a speed of 1 mm / min until a maximum force of 2 MPa was reached. The compressive force (in kPa) required to reach at least 60% compression was recorded.

[0208] 7) Coating weight The coating weight of the polymer foam layer was measured by cutting 100 cm from the sample layer using a circle cutter. 2 The sample was measured by weighing it. Then, the coating weight was calculated in g / m². 2 It was converted to [a certain value].

[0209] 8) Thickness The thickness of the polymer foam layer was measured using a thickness gauge.

[0210] 9) Density Density of polymer layer (g / m³) 3 (Unit) is the coating weight of the foam layer (g / m²) 2 The calculation was performed by dividing the units by their thickness (in meters).

[0211] 10) SEM Microscope Image The polymer foam images were obtained from SEM micrographs recorded with a desktop microscope TM3030, available from Hitachi High-Tech Corporation.

[0212] raw materials: The following raw materials were used in the example.

[0213] DOWSIL 3-8235 is a two-component, room-temperature curing silicone rubber foam compound that is commercially available under the trade name DOWSIL and is obtained from Dow Chemical Company (Midland, MI, United States).

[0214] VTV750 is a two-component, room-temperature curable liquid silicone rubber with a Shore hardness of A40, commercially available from Renishaw PLC in the UK.

[0215] Ultralux glass beads (particle size distribution of 600-1300 micrometers), obtained from Weissker GmbH (Germany).

[0216] OL104LEO is a product sold under the trade name MARTINAL by Martinswerk GmbH in Germany, with a d size in the range of 1.7 to 2.1 micrometers. 50 It is aluminum hydroxide having [a specific property].

[0217] CF30 is a mineral fiber with a length of 300 micrometers, commercially available from Lapinus Fibers BV (The Netherlands) under the trade name COATFORCE CF30.

[0218] RN 50 / 50 is a PET solid film that is commercially available under the trade name HOSTAPHAN RN50 / 50, obtained from Mitsubishi Polyester Film (Greer, SC, United States).

[0219] Examples: General method for preparing an exemplary buffer article (Example 1): An exemplary handmade cushioning article for Example 1 was prepared according to the following procedure.

[0220] DOWSIL 3-8235 components A and B were filled into a unique cartridge system equipped with a dynamic mixing head (3M 05846 Pneumatic Dynamic Mixing System, available from 3M Company (St. Paul, MN, United States)). The cartridge had a dynamic mixing nozzle adapted to a 1:1 volumetric mixing ratio and a 1:1 system (3M 05847 dynamic mixing nozzle also available from 3M). By applying a pressure of 4 bar, the dispensing device piston extruded the material through a nozzle rotating at 2000-3000 revolutions per minute (RPM). This mixture was then coated onto a PET liner with a knife coater. 10 grams (g) of Ultralux glass beads were spread using a bead spreader device onto a 20 × 50 cm (0.1 m) sheet. 2 Spread it evenly over the area of ​​) and this is 100g / m 2 This amount was equivalent to [amount]. Immediately after spreading the glass beads, the sample was covered with a second liner and pressed onto the silicone layer. The resulting sheet expanded, and the reaction was completed by placing the sheet in an 80°C forced-air oven for 10 minutes.

[0221] General manual preparation method for comparative buffer article (Comparative Example CE-1): An exemplary homemade comparative buffer article CE-1 was prepared as described in Example 1 above, except that the polymer foam layer did not incorporate any glass beads and the mixture was coated between two PET liners. The curing reaction was completed by placing the sheet in a forced-air oven at 80°C for 10 minutes.

[0222] General method for preparing an exemplary buffer article (Example 2): An exemplary handmade cushioning article for Example 2 was prepared according to the following procedure.

[0223] DOWSIL 3-8235 components A and B were filled into a 200 mL two-component cartridge system manufactured by Adchem GmbH (Wendelstein, Bayern, Germany) in a 1:1 volume mixing ratio (200 mL F system cartridge). The two-component silicone system was mixed using a static mixer (MFH10-18T) with a dispensing gun at a pneumatic pressure of 4 bar. After releasing 50 g of the mixed silicone into a jar, the mixture was further homogenized by hand for 10 seconds using a wooden spatula. This mixture was then coated between two layers of RN 50 / 50 solid film using a knife coater. The resulting sheet expanded, and the reaction was completed by placing the sheet in an 80°C forced-air oven for 10 minutes.

[0224] Holes with a diameter of 3 mm were perforated in the obtained polymer foam layer using a 3 mm punch and hammer. The perforated holes had a rectangular pattern at a distance of 15 × 15 mm.

[0225] Liquid silicone rubber filler formulations (precursors for spacer elements) were prepared by mixing the agents specified in Table 2, VTV750, OL104LEO, and CF30, in a speed mixer at 2000 RPM for 2 minutes. [Table 2]

[0226] Before casting the liquid silicone rubber, a certain amount (specified in Table 2) of CAT750 catalyst was added and mixed using a speed mixer at 2000 RPM for 40 seconds. The liquid silicone rubber was then filled into the perforated holes in the polymer foam layer using a knife coating process. The gaps in the knife coater corresponded to the thickness of the foam, i.e., the silicone rubber spacer elements had the same thickness as the uncompressed polymer foam layer. The resulting structure was cured at 80°C for 2 hours to obtain the buffer article of Example 2.

[0227] General manual preparation method for comparative buffer articles (Comparative Example CE-2): An exemplary homemade comparative buffer article CE-2 was prepared as described above, except that the polymer foam layer did not incorporate any perforated holes or spacer elements.

[0228] Exemplary cushioning articles (Examples 1 and 2) and comparative examples CE-1 and CE-2: Table 3 shows exemplary cushioning materials and comparative examples. Table 3 specifies complementary processing parameters. Comparative examples CE-1 and CE-2 feature neat polymer foam layers without spacer elements. Thermal insulation performance tests (Test 2) were conducted, and the results are shown in Tables 4 and 5. [Table 3]

[0229] Thermal insulation performance (Test 2) [Table 4] [Table 5] The following are exemplary embodiments. [Item 1] A cushioning item, A non-syntactic polymer foam layer, A plurality of spacer elements arranged within the polymer foam layer An article comprising, wherein each spacer element is at least partially embedded within the polymer foam layer, and each spacer element has a size greater than 200 micrometers. [Item 2] The article according to item 1, wherein the polymer foam layer comprises a material having a weight loss of 70% or less after 3 minutes at 600°C, as measured according to the thermal stability test method described in the experimental section. [Item 3] The article according to item 1 or 2, wherein the polymer foam layer comprises a material selected from the group consisting of elastomer materials, thermoplastic materials, thermoplastic elastomer materials, thermoplastic non-elastomer materials, thermosetting materials, and any combination or mixture thereof. [Item 4] The article according to any one of items 1 to 3, wherein the polymer foam layer comprises a material selected from the group consisting of silicone elastomers, particularly silicone rubber, and more specifically, organopolysiloxane polymers. [Item 5] The article according to any one of items 1 to 4, wherein the polymer foam layer reaches at least 60% compression when measured according to the compression test method described in the experimental section, when a compressive force of 700 kPa or less is applied. [Item 6] The article described in any one of items 1 to 5, wherein the spacer element is a high-density element. [Item 7] The article according to any one of items 1 to 6, wherein the plurality of spacer elements are uniformly arranged within the polymer foam layer along a plane formed by the polymer foam layer. [Item 8] The article according to any one of items 1 to 7, wherein the plurality of spacer elements are completely embedded within the polymer foam layer. [Item 9] An article as described in any one of items 1 to 8, wherein each spacer element has a size greater than 250 micrometers. [Item 10] An article as described in any one of items 1 to 9, wherein each spacer element has an aspect ratio AR (ratio x / y), where x is the length of the maximum dimension of the spacer element and y is the length of the minimum dimension of the spacer element, and the aspect ratio of each spacer element is 5 or less. [Item 11] The article described in any one of items 1 to 10, wherein each spacer element has an overall shape selected from the group consisting of circular, semicircular, elliptical, square, triangular, rectangular, rhombus, polygonal, linear stripe, nonlinear stripe, curved stripe, and any combination thereof. [Item 12] The article according to any one of items 1 to 11, wherein the spacer element comprises a material selected from the group consisting of elastomer materials, siliceous materials, ceramic materials, metals, thermoplastic materials, thermoplastic elastomer materials, thermoplastic non-elastomer materials, thermosetting materials, and any combination or mixture thereof. [Item 13] A method for manufacturing an article as described in any one of items 1 to 12, A step of providing a polymer foam layer according to any one of items 1 to 5, A step of providing multiple spacer elements as described in any one of items 1 to 12, A method comprising the step of incorporating the plurality of spacer elements into the polymer foam layer so that the plurality of spacer elements are arranged within the polymer foam layer and each spacer element is at least partially embedded within the polymer foam layer. [Item 14] Use of any of the items described in items 1 through 12 for industrial purposes, particularly for thermal management purposes, and more specifically in the transportation industry. [Item 15] Use of any of the articles described in items 1 through 12 as thermal barriers, particularly thermal runaway barriers, in rechargeable electrical energy storage systems, especially in battery modules.

Claims

1. A cushioning item, A non-syntactic polymer foam layer, A plurality of spacer elements arranged within the polymer foam layer Each spacer element is at least partially embedded within the polymer foam layer, and each spacer element has a maximum size greater than 300 micrometers and less than or equal to 6000 micrometers. The polymer foam layer and the spacer element are composed of different materials. The polymer foam layer comprises a material selected from the group consisting of silicone elastomers, The spacer element includes a material selected from the group consisting of elastomer materials, siliceous materials, ceramic materials, thermoplastic materials, thermoplastic elastomer materials, thermoplastic non-elastomer materials, thermosetting materials, and any combination or mixture thereof. Each spacer element has an aspect ratio AR (ratio x / y), where x is the maximum length of the spacer element and y is the minimum length of the spacer element, and the aspect ratio of each spacer element is 5 or less. Goods.

2. The article according to claim 1, wherein the polymer foam layer comprises a material in which the weight loss after placing a test specimen in a porcelain crucible in a muffle furnace at 600°C for 3 minutes, removing it, and allowing it to cool is 70% or less.

3. The article according to any one of claims 1 to 2, wherein when the upper plate of the compression testing machine is moved at a speed of 1 mm / min until a maximum force of 2 MPa is reached, the compressive force required for the polymer foam layer to reach at least 60% of its compression value is 700 kPa or less.

4. The article according to any one of claims 1 to 3, wherein the plurality of spacer elements are completely embedded within the polymer foam layer.

5. The article according to any one of claims 1 to 4, wherein each spacer element has an overall shape selected from the group consisting of circular, semicircular, elliptical, square, triangular, rectangular, rhombus, polygonal, and any combination thereof.

6. A method for manufacturing an article according to any one of claims 1 to 5, The process of providing the polymer foam layer, The process of providing the aforementioned plurality of spacer elements, A method comprising the step of incorporating the plurality of spacer elements into the polymer foam layer so that the plurality of spacer elements are arranged within the polymer foam layer and each spacer element is at least partially embedded within the polymer foam layer.

7. Use of the article according to any one of claims 1 to 5 as a thermal barrier in a rechargeable electrical energy storage system.

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