Fire-resistant mattress

Abstract

The invention relates to a fire-resistant insulation that may include a silicon-gas gel composite consisting of silicon and gas gel, wherein the silicon-gas gel composite may contain a predetermined amount of gas gel.

Description

fireproof pad

[0001] Cross-citation with related application(s)

[0002] This application claims the benefit of priority to Korean Patent Application No. 10-2024-0059995, filed May 7, 2024, Korean Patent Application No. 10-2024-0074276, filed June 7, 2024, and Korean Patent Application No. 10-2025-0044125, filed April 4, 2025, the entire contents of which are incorporated herein by reference.

[0003] The present invention relates to a fireproof pad, and more particularly, to a fireproof pad comprising an insulating layer comprising a silicone-aerogel composite.

[0004] As technological developments and demand for mobile devices increase, the demand for secondary batteries as an energy source is rapidly increasing. In particular, secondary batteries are attracting significant attention as an energy source not only for mobile devices such as cell phones, digital cameras, laptops, and wearable devices, but also for powertrains such as electric bicycles, electric cars, and hybrid electric vehicles.

[0005] Secondary battery cells are manufactured by embedding electrode assemblies together with electrolytes in a secondary battery case, and the electrode assemblies are manufactured by stacking and / or winding a cathode, a separator, and anode. The manufactured battery cells are stacked in multiple pieces to form a battery module or battery pack.

[0006] As the cells are driven, heat may be generated in the battery cells, and if the heat is transferred to and accumulated in adjacent battery cells, battery thermal propagation may occur.

[0007] Preventing battery thermal runaway is crucial for the safety of electric vehicle batteries, and extensive research is underway. Currently, the industry utilizes silicone or polyurethane materials interposed between battery cells as fire-resistant pads. However, these materials are inadequate in preventing the ultra-high-temperature flames that form during battery thermal runaway. Therefore, research into highly fire-resistant fire-resistant pads and their manufacturing methods continues.

[0008] The present invention is intended to solve the above problem and provides a fire-resistant pad with excellent insulation properties.

[0009] The refractory pad of the present invention comprises an insulating layer comprising a silicone-aerogel composite including silicone and aerogel, wherein the content of the aerogel in the silicone-aerogel composite is 0.5 wt% or more and 40 wt% or less based on the total weight of the insulating layer.

[0010] In a specific embodiment, the content of the silicon may be 60 wt% or more and 99.5 wt% or less.

[0011] In one embodiment, the content of the aerogel may be 15 wt% or more and 30 wt% or less.

[0012] In one embodiment, the thickness of the insulating layer may be 0.1 mm or more and 5 mm or less.

[0013] In one embodiment, the insulating layer may further include a fire-resistant layer disposed on at least one surface thereof and including a fire-resistant material including at least one of a non-combustible material and a flame retardant material.

[0014] In one embodiment, the thickness of the refractory layer may be 0.1 mm or more and 5 mm or less.

[0015] In one embodiment, the refractory layer may be disposed on both sides of the insulating layer.

[0016] In one embodiment, the invention may further include an adhesive layer disposed between the refractory layer and the insulating layer.

[0017] In one embodiment, the refractory material may include at least one of mica fibers, glass fibers, basalt fibers, ceramic paper, and vermiculite-coated glass fiber cloth.

[0018] In one embodiment, the first layer, the second layer, the third layer, the fourth layer, and the fifth layer may be sequentially laminated, wherein the second layer and the fourth layer may be the insulating layer, and the first layer, the third layer, and the fifth layer may be the fire-resistant layer. In one embodiment, the first layer and the fifth layer may include the same fire-resistant material, and the third layer may include a fire-resistant material different from the first layer and the fifth layer.

[0019] In one embodiment, the first layer, the third layer, and the fifth layer may comprise the same refractory material.

[0020] In one embodiment, the first layer and the fifth layer may be ceramic paper, and the third layer may be glass fiber cloth coated with vermiculite.

[0021] In one embodiment, the first layer, the third layer, and the fifth layer may be ceramic paper.

[0022] In one embodiment, the thicknesses of the second layer and the fourth layer may be smaller than the thicknesses of the first layer, the third layer, and the fifth layer.

[0023] In one embodiment, the thickness of each of the first layer, the third layer, and the fifth layer may be 0.5 mm or more and 3 mm or less.

[0024] In one embodiment, the thickness of each of the second layer and the fourth layer may be 0.1 mm or more and 2 mm or less.

[0025] In one embodiment, the aerogel may comprise silica gel.

[0026] In one embodiment, the silicone may comprise a poly(dimethyl siloxane) (PDMS) resin, and optionally further comprise at least one of a crosslinking agent and a catalyst.

[0027] In one embodiment, based on the total blending amount of the silicone-aerogel composite, the content of the polydimethylsiloxane resin may be 47 wt% or more and 99.5 wt% or less, the content of the crosslinking agent may be 0 wt% or more and 10 wt% or less, and the content of the catalyst may be 0 wt% or more and 3 wt% or less.

[0028] In one embodiment, the thermal conductivity of the refractory pad may be greater than or equal to 10 mW / m·K and less than or equal to 200 mW / m·K.

[0029] In one embodiment, the refractory pad may have a stress of 250 kPa or less at 40% strain.

[0030] In one embodiment, the refractory pad may have a residual viscosity of at least 50 wt% at 1000°C.

[0031] In one embodiment, the refractory pad may have a thermal decomposition initiation temperature of 300°C or higher.

[0032] In one embodiment, the refractory pad may have a heat of combustion of greater than 5000 cal / g.

[0033] In one embodiment, the refractory pad may have a thickness of 0.2 mm or more and 5 mm or less.

[0034] In one embodiment, the refractory pad may have a thickness reduction rate of 40% or less when a pressure of 220 kPa is applied.

[0035] In one embodiment, the refractory pad may have a thickness of 0.12 mm or more and 3 mm or less when a pressure of 220 kPa is applied.

[0036] The refractory pad of the present invention can exhibit excellent insulation properties by including an insulation layer comprising a silicone-aerogel composite.

[0037] Figure 1 is a cross-sectional view of a refractory pad of one embodiment.

[0038] Figure 2 is a perspective view schematically illustrating one end of the refractory pad of Figure 1.

[0039] Figure 3 is a cross-sectional view of a refractory pad of one embodiment.

[0040] Figure 4 is a cross-sectional view of a refractory pad of one embodiment.

[0041] Figure 5 is a cross-sectional view of a refractory pad of one embodiment.

[0042] Figure 6 is a graph showing the TGA analysis results of the refractory pad of Example 2.

[0043] Figure 7 is a graph showing the TGA analysis results of a non-combustible material according to one embodiment.

[0044] Hereinafter, various embodiments of the present invention will be described in detail with reference to the attached drawings so that those skilled in the art can easily implement the invention. The present invention may be implemented in various different forms and is not limited to the embodiments described herein.

[0045] In order to clearly explain the present invention, parts that are not related to the description are omitted, and the same reference numerals are used for identical or similar components throughout the specification.

[0046] Furthermore, the sizes and thicknesses of each component shown in the drawings are arbitrarily indicated for convenience of explanation, and thus the present invention is not necessarily limited to the illustrated components. In the drawings, the thicknesses are enlarged to clearly represent various layers and regions. Furthermore, in the drawings, the thicknesses of some layers and regions are exaggerated for convenience of explanation.

[0047] Furthermore, when we say that a layer, membrane, region, plate, or other part is "on" or "over" another part, this includes not only cases where it is "directly on" the other part, but also cases where there are other parts in between. When we say that a part is "directly on" another part, we mean that there are no other parts in between. Furthermore, when we say that a part is "on" or "over" a reference part, we mean that it is located above or below the reference part, and we do not necessarily mean that it is located "above" or "over" the reference part in the opposite direction of gravity.

[0048] Additionally, throughout the specification, whenever a part is said to “include” a component, this does not mean that it excludes other components, but rather that it may include other components, unless otherwise specifically stated.

[0049]

[0050] Hereinafter, the refractory pad of the present invention will be described.

[0051]

[0052] The refractory pad of the present invention,

[0053] An insulating layer comprising a silicone-aerogel composite including silicone and aerogel, wherein the silicone-aerogel composite comprises an aerogel in an amount of 0.5 wt% to 40 wt% based on the total weight of the insulating layer.

[0054] In a specific embodiment, the silicone-aerogel composite may comprise silicone in an amount of 60 wt% or more and 99.5 wt% or less based on the total weight of the insulating layer.

[0055]

[0056] In one embodiment, the refractory pad comprises the insulating layer described above.

[0057] Additionally, in one embodiment, the fireproof pad may further include a fireproof layer disposed on at least one surface of the insulating layer and comprising a fireproof material comprising at least one of a non-combustible material and a flame retardant material.

[0058]

[0059] Figure 1 is a cross-sectional view of a refractory pad of one embodiment.

[0060] Referring to Fig. 1, a fireproof pad (1) of one embodiment includes an insulating layer (LL1) and may further include a fireproof layer (LL2) disposed on at least one surface of the insulating layer (LL1). In Fig. 1, an embodiment in which the fireproof layer (LL2) is disposed on both surfaces of the insulating layer (LL1) is illustrated, but the fireproof pad of the present invention is not limited thereto. For example, the fireproof pad (1) may include only the insulating layer (LL1), or may have a structure in which the fireproof layer (LL2) is disposed on only one surface of the insulating layer (LL1).

[0061] The insulating layer (LL1) includes a silicone-aerogel composite including silicone (SL) and aerogel (AG). Specifically, the insulating layer (LL1) is formed by curing and sheeting the silicone-aerogel composite. The insulating layer (LL1) can exhibit excellent insulating performance by having sufficiently low thermal conductivity by including the aerogel (AG). For example, the thermal conductivity of the insulating layer (LL1) may be 10 mW / m·K or more and 200 mW / m·K or less, preferably 10 mW / m·K or more and 150 mW / m·K or less.

[0062] The insulation layer (LL1) can have a high heat of combustion, for example, a heat of combustion of more than 5000 cal / g (as measured by the Parr Bomb Calorimeter, ISO 1716 standard). This high heat of combustion is a characteristic of the insulation layer (LL1) that includes a silicone-aerogel composite material that mixes silicone and aerogel.

[0063] The insulating layer (LL1) can be easily sheeted by including silicone (SL) and aerogel (AG) in an appropriate ratio. The silicone-aerogel composite has aerogel (AG) present in the form of particles in cured silicone (SL). Specifically, in the silicone-aerogel composite, the content of the aerogel (AG) is 0.5 wt% or more and 40 wt% or less. In addition, the content of the silicone (SL) can be 60 wt% or more and 99.5 wt% or less. The content of the aerogel (AG) is preferably 0.5 wt% or more and 30 wt% or less, more preferably 10 wt% or more and 30 wt% or less, and even more preferably 15 wt% or more and 30 wt% or less. When the content of the aerogel (AG) is less than 0.5 wt%, the insulating properties of the silicone-aerogel composite may be deteriorated. When the content of aerogel (AG) exceeds 40 wt%, padding of the silicone-aerogel composite may become difficult.

[0064] In one embodiment, the aerogel (AG) may comprise silica gel (SiO2). For example, the aerogel (AG) may have a particle size of 0.01 mm to 1.5 mm and a pore diameter of 1 nm to 200 nm.

[0065] In one embodiment, the silicone (SL) comprises a poly(dimethyl siloxane) (PDMS) resin and optionally may further comprise at least one of a crosslinking agent and a catalyst.

[0066] Specifically, polydimethylsiloxane resin has a siloxane skeleton and a vinyl group at the end (PDMS-vinyl terminated, ViMe2SiO(Me2SiO) XIt may be SiMe2Vi). In addition, the molecular weight of the polydimethylsiloxane resin used in the silicone (SL) of the present invention may be 1,000 g / mol or more and 100,000 g / mol or less. The crosslinking agent may be a silicone-based crosslinking agent containing at least one Si-H structure, and for example, polymethylhydrogen siloxane may be used. As the catalyst, a platinum catalyst may be used, or a peroxide-based initiator may be used depending on the curing mechanism.

[0067] In one embodiment, the composition of the silicone (SL) may include a polydimethylsiloxane resin and a crosslinker, a polydimethylsiloxane resin and a catalyst, or a polydimethylsiloxane resin, a crosslinker, and a catalyst.

[0068] Based on the total mixing amount of the silicone-aerogel composite, the content of the polydimethylsiloxane resin may be 47 wt% or more and 99.5 wt% or less, the content of the crosslinking agent may be 0 wt% or more and 10 wt% or less, and the content of the catalyst may be 0 wt% or more and 3 wt% or less.

[0069] However, the composition of the silicone is not limited thereto, and the silicone can further include a known flame retardant additive to enhance the flame retardant effect. For example, the flame retardant additive may include at least one selected from the group consisting of nitrogen-based substances such as guanidine compounds and melamine compounds, phosphate-based substances such as triphenyl phosphate, trixylenyl phosphate, tricresyl phosphate, and triisophenyl phosphate, metal hydroxide-based substances such as Al(OH)3 and Mg(OH)2, ammonium-based substances such as ammonium polyphosphate, ammonium phosphate, and ammonium carbonate, and antimony-based substances.

[0070] The refractory layer (LL2) may include a refractory material comprising at least one of a non-combustible material and a flame retardant material. The refractory material may include at least one of mica fibers, glass fibers, basalt fibers, ceramic paper, and vermiculite-coated glass fiber cloth. Additionally, the refractory material may be provided in a sheet form.

[0071] The fireproof pad (1) of the present invention can have excellent insulation performance and fire resistance by including the aforementioned insulation layer (LL1) and fireproof layer (LL2). In addition, since the fireproof layer (LL2) serves as a support for the insulation layer (LL1), the fireproof pad (1) can secure sufficient flexibility and strength.

[0072]

[0073] Figure 2 is a perspective view schematically illustrating one end of the refractory pad of Figure 1.

[0074] In Fig. 2, one refractory layer (LL2) and one insulation layer (LL1) included in the refractory pad (1) of Fig. 1 are enlarged and illustrated for explanation purposes.

[0075] Referring to Fig. 2, at one end of the refractory pad, the end (EG1) of the insulation layer (LL1) may be positioned inward relative to the end (EG2) of the refractory layer (LL2). Although not shown, at the other end of the refractory pad, the end (EG1) of the insulation layer (LL1) may also be positioned inward relative to the end (EG2) of the refractory layer (LL2). Accordingly, the area of ​​the insulation layer (LL1) may be smaller than the area of ​​the refractory layer (LL2), and the insulation layer (LL1) may not be exposed outside the refractory layer (LL2).

[0076] In addition, the thickness (HH1) of one insulation layer (LL1) may be 0.1 mm or more and 5 mm or less. For example, the thickness (HH1) of the insulation layer (LL1) may be 0.1 mm or more and 3 mm or less, or 0.1 mm or more and 2 mm or less, and specifically, may be 1 mm or 2 mm, but the embodiment is not limited thereto. The thickness (HH2) of one fire-resistant layer (LL2) may be 0.1 mm or more and 5 mm or less. For example, the thickness (HH2) of the fire-resistant layer (LL2) may be 0.1 mm or more and 3 mm or less, or 0.5 mm or more and 2 mm or less. When the thickness (HH1) of the insulation layer (LL1) is less than 0.1 mm, the insulation performance of the fire-resistant pad (1) may be deteriorated. When the thickness (HH2) of the fire-resistant layer (LL2) is less than 0.1 mm, the fire resistance performance of the fire-resistant pad (1) may be deteriorated. If the thickness (HH1, HH2) of either the insulation layer (LL1) or the fire-resistant layer (LL2) exceeds 5 mm, the volume of the fire-resistant pad (1) increases excessively, making it difficult to secure energy density relative to the volume of the battery when applied to the battery. The thickness (HH1) of the insulation layer (LL1) and the thickness (HH2) of the fire-resistant layer (LL2) may be the same as or different from each other, and for example, the thickness (HH1) of the insulation layer (LL1) and the thickness (HH2) of the fire-resistant layer (LL2) may be the same as 1 mm, but the embodiment is not limited thereto.

[0077] The overall thickness of the refractory pad (1) may be 0.2 mm or more and 5 mm or less. When the refractory pad (1) includes only an insulating layer (LL1), it may include two or more insulating layers (LL1).

[0078] For example, the overall thickness of the refractory pad (1) may be 1 mm or more and 5 mm or less, but the embodiment is not limited thereto.

[0079] Meanwhile, the thickness (HH1) of the aforementioned insulation layer (LL1), the thickness (HH2) of the fire-resistant layer (LL2), and the thickness of the fire-resistant pad (1) are thicknesses measured without being subjected to separate pressure.

[0080] In one embodiment, the refractory pad (1) of the present invention may have a thickness reduction rate of 40% or less when a pressure of 220 kPa is applied. That is, the refractory pad (1) may have a thickness reduction rate of 0% or more and 40% or less when a pressure of 220 kPa is applied. Specifically, the thickness of the refractory pad (1) is 0.2 mm or more and 5 mm or less, and the thickness may be 0.12 mm or more and 3 mm or less when a pressure of 220 kPa is applied to the refractory pad (1). In addition, the refractory pad (1) of the present invention may have a thickness reduction rate of 25% or less, for example, 20% or less, when a pressure of 30 kPa is applied. That is, the refractory pad (1) may have a thickness reduction rate of 0% or more and 25% or less when a pressure of 30 kPa is applied. Specifically, the thickness of the refractory pad (1) is 0.2 mm or more and 5 mm or less, and when a pressure of 30 kPa is applied to the refractory pad (1), the thickness may be 0.15 mm or more and 3.75 mm or less.

[0081] Meanwhile, referring to FIGS. 1 and 2 together, in one embodiment, the insulating layer (LL1) may be arranged to have a single plane shape extending in a plane. This is because, in the manufacturing process of the refractory pad (1), the silicone-aerogel composite is arranged in a single layer shape and then cured. However, the shape of the insulating layer (LL1) is not limited thereto.

[0082]

[0083] Figure 3 is a cross-sectional view of a refractory pad of one embodiment.

[0084] Referring to FIG. 3, in the refractory pad (1-1) of one embodiment, the insulating layers (LL1-1) may be arranged in a stripe shape with a predetermined interval (GP). This is because, in the manufacturing process of the refractory pad (1-1), the silicone-aerogel composite is arranged in a stripe shape and then cured. Since the silicone-aerogel composite is in powder form, it can be arranged in a stripe shape. The refractory pad (1-1) of one embodiment includes an interval (GP) in which air exists between the insulating layers (LL1-1), so that the insulating performance can be further improved.

[0085]

[0086] Figure 4 is a cross-sectional view of a refractory pad of one embodiment.

[0087] Referring to FIG. 4, a fireproof pad (1-2) of one embodiment may further include an insulating layer (LL1), a fireproof layer (LL2) disposed on at least one surface of the insulating layer (LL1), and an adhesive layer (LL3) disposed between the insulating layer (LL1) and the fireproof layer (LL2). The adhesive layer (LL3) is a layer formed by curing an adhesive material, and the specific composition of the adhesive material will be described later.

[0088] For example, a fireproof pad (1-2) of one embodiment may include an insulating layer (LL1), a fireproof layer (LL2) disposed on both sides of the insulating layer (LL1), and an adhesive layer (LL3) disposed between the insulating layer (LL1) and the fireproof layer (LL2).

[0089] The adhesive layer (LL3) is provided for the purpose of enhancing the adhesive strength between the insulation layer (LL1) and the fire-resistant layer (LL2). In particular, when the content of the aerogel (AG) is 30 wt% or more, the adhesive layer (LL3) may be provided to supplement the adhesive strength. However, the content of the aerogel (AG) is not limited and the adhesive layer (LL3) may be additionally provided as needed.

[0090] The adhesive material included in the adhesive layer (LL3) may be a known adhesive material such as a silicone-based adhesive material, an acrylic-based adhesive material, or an epoxy-based adhesive material. For example, the adhesive layer (LL3) may include a silicone-based adhesive material, and the silicone-based adhesive material may include a polydimethylsiloxane resin, a crosslinking agent, and a catalyst, and optionally further include a coupling agent. The polydimethylsiloxane resin may have a siloxane skeleton and may include one or more vinyl groups. In addition, the viscosity of the polydimethylsiloxane resin used in the silicone-based adhesive material of the present invention may be 5 cP or more and 5,000 cP or less. The crosslinking agent may be a silicone-based crosslinking agent including at least one Si-H structure, for example, polymethylhydrogen siloxane may be used. The catalyst may be a platinum catalyst. The coupling agent may be a silane-based coupling agent represented by X-Si-OR3 (X=vinyl group, epoxy group, amino group, methacryloxy group, or mercapto group, R=methoxy group, ethoxy group, dialkoxy group, or trialkoxy group). Since the silicone-based adhesive material basically has PSA (Pressure Sensitive Adhesive) characteristics, it can have sufficient adhesive strength even without a coupling agent. However, depending on the type of refractory material included in the refractory layer (LL2), the adhesive strength can be further improved by compounding the silicone-based adhesive material to include a coupling agent.

[0091] For example, an adhesive material of one embodiment may include a polydimethylsiloxane resin, a crosslinking agent, a catalyst, and a coupling agent. For example, based on the total weight of the adhesive material, the content of the polydimethylsiloxane resin may be greater than 77 wt% and less than 100 wt%, the content of the crosslinking agent may be greater than 0 wt% and less than 10 wt%, the content of the catalyst may be greater than 0 wt% and less than 3 wt%, and the content of the coupling agent may be greater than 0 wt% and less than 10 wt%. For example, based on the total weight of the adhesive material, the content of the polydimethylsiloxane resin may be 95 wt%, the content of the crosslinking agent may be 1 wt%, the content of the catalyst may be 0.5 wt%, and the content of the coupling agent may be 3.5 wt%, but the embodiment is not limited thereto.

[0092] A refractory pad (1-2) of one embodiment includes an adhesive layer (LL3) disposed between an insulating layer (LL1) and a refractory layer (LL2), thereby being able to strongly bond the insulating layer (LL1) and the refractory layer (LL2) regardless of the content of the aerogel (AG).

[0093]

[0094] Meanwhile, the refractory pad of the present invention,

[0095] 1st floor;

[0096] A second layer comprising a silicone-aerogel composite and disposed on the first layer;

[0097] A third layer disposed on the second layer;

[0098] a fourth layer comprising the silicone-aerogel composite and disposed on the third layer; and

[0099] A fifth layer disposed on the fourth layer; including;

[0100] Each of the first layer, the third layer, and the fifth layer comprises a refractory material.

[0101]

[0102] Figure 5 is a cross-sectional view of a refractory pad of one embodiment.

[0103] Referring to FIG. 5, a refractory pad (1-3) according to one embodiment is

[0104] It includes a first layer (10), a second layer (20), a third layer (30), a fourth layer (40), and a fifth layer (50) sequentially laminated along the first direction (DR1),

[0105] The second layer (20) and the fourth layer (40) are the aforementioned insulation layers (LL1),

[0106] The first layer (10), the third layer (30), and the fifth layer (50) may be the aforementioned refractory layer (LL2).

[0107]

[0108] Each of the first layer (10), the third layer (30), and the fifth layer (50) comprises a refractory material. As described above, the refractory material may comprise at least one of mica fibers, glass fibers, basalt fibers, ceramic paper, and vermiculite-coated glass fiber cloth.

[0109] The first layer (10), the third layer (30), and the fifth layer (50) may comprise the same refractory material, or at least one may comprise a different refractory material than the others. In one embodiment, the first layer (10) and the fifth layer (50) may comprise the same refractory material, while the third layer (30) may comprise a different refractory material than the first layer (10) and the fifth layer (50). Alternatively, in one embodiment, the first layer (10), the third layer (30), and the fifth layer (50) may comprise the same refractory material.

[0110] In one embodiment, the first layer (10) and the fifth layer (50) may be ceramic paper. Ceramic paper is made by applying an inorganic and / or organic binder to ceramic fibers and then compressing them to form a paper. For example, the first layer (10) and the fifth layer (50) may each use ceramic paper, and specifically, alkaline earth silicate (AES), such as Morgan's Superwool product, may be used.

[0111] In one embodiment, the third layer (30) may be a vermiculite-coated glass fiber cloth (hereinafter, vermiculite cloth). Vermiculite cloth is made by weaving a material in which vermiculite is coated on glass fiber. For example, the vermiculite cloth may include 46 to 50 wt% of silicon, 15 to 18 wt% of aluminum, 14 to 18 wt% of magnesium, 14 to 17 wt% of iron, and 1 to 5 wt% of titanium in its composition.

[0112] Alternatively, the third layer (30) may be ceramic paper. That is, in one embodiment, the first layer (10), the third layer (30), and the fifth layer (50) may be ceramic paper.

[0113] Alternatively, in one embodiment, the first layer (10), the third layer (30), and the fifth layer (50) may be a gypsum board.

[0114] As above, the first layer (10), the third layer (30), and the fifth layer (50) are refractory layers (LL2) including refractory materials, and the refractory pad (1-3) including the same can exhibit excellent refractory properties.

[0115] The second layer (20) and the fourth layer (40) are the aforementioned insulating layers (LL1). That is, the second layer (20) and the fourth layer (40) include the aforementioned silicone-aerogel composite. Specifically, the second layer (20) and the fourth layer (40) are layers formed by mixing silicone (SL) and aerogel (AG) to form a silicone-aerogel composite, and then curing the silicone-aerogel composite. The description of silicone (SL) and aerogel (AG) is equally applicable to the aforementioned content.

[0116] The second layer (20) and the fourth layer (40) can exhibit excellent insulating properties and sufficient adhesive properties by including such a silicone-aerogel composite. The second layer (20) can bond the first layer (10) and the third layer (30), and the fourth layer (40) can bond the third layer (30) and the fifth layer (50). In addition, since the second layer (20) and the fourth layer (40) are adhesive layers, their thicknesses can be smaller than the thicknesses of the first layer (10), the third layer (30), and the fifth layer (50). For example, the thicknesses of the first layer (10), the third layer (30), and the fifth layer (50) can be 0.5 mm or more and 3 mm or less, and the thicknesses of the second layer (20) and the fourth layer (40) can be 0.1 mm or more and 2 mm or less. However, the thickness of each layer is not limited thereto. Meanwhile, in this specification, thickness is defined as the length measured in the first direction (DR1).

[0117] As above, each of the second layer (20) and the fourth layer (40) may be an insulating adhesive layer that has insulating properties and performs an adhesive layer function.

[0118] The refractory pad (1-3) of the present invention can exhibit excellent refractory properties and insulation properties by including the first to fifth layers (10, 20, 30, 40, 50) described above.

[0119]

[0120] In this way, the fireproof pad (1, 1-1, 1-2, 1-3) of the present invention can exhibit excellent fire resistance and heat insulation. In addition, when the fireproof pad (1, 1-1, 1-2, 1-3) is applied to a battery pack, the fireproof pad (1, 1-1, 1-2, 1-3) can play a role in blocking the spread of flame and heat. Specifically, the fireproof pad (1, 1-1, 1-2, 1-3) of the present invention can be placed between battery cells included in the battery pack in the first direction (DR1, see FIG. 5), and exhibits excellent heat insulation, thereby effectively preventing heat from spreading to adjacent battery cells. Therefore, the fireproof pad (1, 1-1, 1-2, 1-3) of the present invention can minimize heat transfer between battery cells, prevent heat from being concentrated in a specific cell, and prevent thermal runaway from occurring in advance.

[0121] Hereinafter, embodiments of the invention will be described in detail so that those skilled in the art can easily implement the invention. However, the present invention may be implemented in various different forms and is not limited to the embodiments described herein.

[0122]

[0123] 1. Preparation of the insulation layer of Examples 1 to 3 and Comparative Examples 1 to 4

[0124]

[0125] Preparation of the insulation layer of Example 1

[0126] A solid silicone-aerogel composite was formed by mixing solvent-free silicone and aerogel in a weight ratio of 87.18:12.82. The silicone was PDMS resin, Dowsil from DOW. TM 7626 was used, and Dow Syl-off was used as a crosslinking agent. TM 7028 was used, and Dow's Syl-off was used as a Pt catalyst. TM 4000 was used. Cabot EV5200 was used as the aerogel.

[0127] The manufactured silicone-aerogel composite was subjected to a test at 150°C with a strength of 1.5 kgf / cm 2 The insulating layer of Example 1 having a thickness of 2 mm was manufactured by hot-pressing for 30 seconds to form a pad and further heat-curing in an oven at 150°C for 10 minutes.

[0128]

[0129] Preparation of the insulation layer of Example 2

[0130] The insulation layer of Example 2 was manufactured in the same manner as the insulation layer of Example 1, except that the silicone and aerogel were mixed in a weight ratio of 83.61:16.39.

[0131]

[0132] Preparation of the insulation layer of Example 3

[0133] The insulation layer of Example 3 was manufactured in the same manner as the insulation layer of Example 1, except that the silicone and aerogel were mixed in a weight ratio of 80.31:19.69.

[0134]

[0135] Manufacturing of insulation layer of comparative example 1

[0136] Only silicone was used without aerogel. That is, the insulation layer of Comparative Example 1 was manufactured in the same manner as the insulation layer of Example 1, except that silicone was used instead of the silicone-aerogel composite in Example 1.

[0137]

[0138] Manufacturing of insulation layer of comparative example 2

[0139] An insulating layer of Comparative Example 2 was prepared in the same manner as the insulating layer of Example 1, except that the silicone and aerogel were mixed in a weight ratio of 50:50. However, padding of the silicone-aerogel composite was not achieved.

[0140]

[0141] Manufacturing of insulation layer of comparative example 3

[0142] An insulating layer of Comparative Example 3 was prepared in the same manner as the insulating layer of Example 1, except that the silicone and aerogel were mixed in a weight ratio of 30:70. However, padding of the silicone-aerogel composite was not achieved.

[0143]

[0144] Manufacturing of insulation layer of comparative example 4

[0145] Pure aerogel containing 100% aerogel without silicone was prepared. It was provided in powder form and was not padded.

[0146]

[0147] 2. Evaluation of thermal conductivity of insulation layers of Examples 1 to 3 and Comparative Examples 1 to 4

[0148] For the insulation layers of Examples 1 to 3 and Comparative Examples 1 to 4 manufactured above, thermal conductivity was evaluated using the TPS method (ISO 2207-2). For Comparative Examples 2 to 4, which were not padded, thermal conductivity was measured in powder form.

[0149] Thermal conductivity (mW / m K) Padded or not Example 1131.9O Example 2107.2O Example 381.9O Comparative Example 1231O Comparative Example 245X Comparative Example 340.3X Comparative Example 429.3X

[0150] Referring to Table 1 above, it can be confirmed that the insulation layers of Examples 1 to 3 have sufficiently low thermal conductivity of about 150 mW / m·K or less, specifically, 131.9 mW / m·K or less, and thus have excellent insulation properties. In particular, it was confirmed that the insulation layers of Examples 2 and 3 have even lower thermal conductivity of about 110 mW / m·K or less, specifically, 107.2 mW / m·K or less, and optimized insulation properties as the aerogel content becomes 15 wt% or more. In addition, it can be confirmed that the insulation layers of Examples 1 to 3 have sufficient insulation performance and can be easily padded by including 0.5 wt% or more and 40 wt% or less of aerogel, or 10 wt% or more and 30 wt% or less of silicone, and 60 wt% or more and 99.5 wt% or less of silicone, or 70 wt% or more and 90 wt% or less. In particular, it can be confirmed that the insulation layers of Examples 2 and 3 have excellent insulation performance and are padded without deterioration of mechanical properties by including 15 wt% or more and 30 wt% or less of aerogel and 70 wt% or more and 85 wt% or less of silicone.

[0151] The insulation layer of Comparative Example 1 did not contain aerogel, so its thermal conductivity was very high and it is expected that it will be difficult to expect insulation performance.

[0152] The insulation layers of Comparative Examples 2 and 3 had low thermal conductivity when the aerogel content exceeded 40 wt%, but did not become padded.

[0153] The insulation layer of Comparative Example 4 is 100% aerogel, has very low thermal conductivity, but exists in powder form and is not padded, so it cannot be applied as a fire-resistant pad.

[0154]

[0155] 3. Compressive Force Deflection (CFD)

[0156] Compression evaluation was conducted on the refractory pads of Examples 4 and 5 below.

[0157] The refractory pad of Example 4 includes the following insulating layer and a refractory layer disposed on both sides of the insulating layer. The insulating layer was manufactured in the same manner as the insulating layer of Example 1, except that silicone and aerogel were mixed in a weight ratio of 75:25. The refractory layer was made of ceramic paper.

[0158] For the compression evaluation, an experiment was conducted with a sample having a total thickness of 20 mm by overlapping 10 sheets of the refractory pad of Example 4, each 2 mm thick.

[0159]

[0160] The refractory pad of Example 4 was tested using Instron's UTM tensile tester, and compression evaluation (Compressive Force Deflection, CFD) was performed under the following conditions.

[0161] -PRELOAD: 140 Pa

[0162] -PREFLEX: 40kPa, 1 time, 1mm / min

[0163] -SPECIMEN SIZE: 50.0mm x 50.0mm

[0164] -SPECIMEN THICK: 24.25mm

[0165] -Pressure: 1kPa

[0166] -COMPRESSION Speed: 1mm / min

[0167] -holding time: 0 min

[0168]

[0169] The fire-resistant pad of Example 5 is made by laminating 10 sheets of the fire-resistant pad of Example 4 and then packaging them with a PET film having a thickness of 50 μm as a packaging material.

[0170] The refractory pad of Example 5 was tested using Instron's UTM tensile tester, and compression evaluation (Compressive Force Deflection, CFD) was performed under the following conditions.

[0171] -PRELOAD: 300 Pa

[0172] -PREFLEX: -

[0173] -SPECIMEN SIZE: 50.0mm x 50.0mm

[0174] -SPECIMEN THICK: 25.60mm

[0175] -Pressure: 1kPa

[0176] -COMPRESSION Speed: 1mm / min

[0177] -holding time: 0 min

[0178]

[0179] The results of the CFD evaluation for the refractory pads of Examples 4 and 5 are shown in Table 2 below.

[0180] Classification Example 4 Example 5 Strain (%) Stress (kPa) 51.7 1.8 10 3.42 9 15 6.55 6 20 13.7 10.5 25 31.8 20.43 0 69 40.93 5 129 67 9.94 0 220 01 46.64 5 345 22 49.75 0 5 20.84 11.75 5 7 7 4.5 7 0 1.26 0 11 7 9.41 33 4.76 5 19 40.22 7 47.97 0 35 86.95 427.47 5 7 213.89 0 61.68 0 12 15 8.9 12 15 1.9

[0181] Referring to Table 2 above, it can be confirmed that the refractory pads of Examples 4 and 5 have significantly lower stress in the range of Strain 0% to 40%, which is the initial compression ratio, and in particular, the stress at Strain 40% is 220 kPa, which is a stress of 250 kPa or less.

[0182] Accordingly, it can be confirmed that the refractory pad of the present invention has good compressibility and excellent flexibility in the range of 0% to 40% of the initial compression ratio, Strain.

[0183]

[0184] 4. Evaluation of Thermogravimetric Analysis (TGA)

[0185] A thermal gravimetric analysis (TGA) evaluation was performed on the refractory pad of Example 2 manufactured above and the non-combustible material of one example under the following conditions. The non-combustible material of one example was Super Wool from Morgan.

[0186] [Experimental conditions]

[0187] Ramping rate: 10℃ / min,

[0188] Temperature range: 50℃- 1000℃,

[0189] Atmosphere: air

[0190]

[0191] Figure 6 is a graph showing the TGA analysis results of the refractory pad of Example 2.

[0192] Figure 7 is a graph showing the TGA analysis results of a non-combustible material according to one embodiment.

[0193] Specifically, graph a in FIG. 6 shows the residual rate (wt%) of the refractory pad of Example 2. graph b in FIG. 6 shows the residual rate (wt%) of aerogel in the refractory pad of Example 2. graph c in FIG. 6 shows the residual rate (wt%) of silicone in the refractory pad of Example 2. graph 7 shows the residual rate (wt%) of non-combustible material.

[0194] Referring to Figures 6 and 7, the survival rate of each configuration at 1000°C is shown in Table 3 below.

[0195] Residual ratio (weight %) of the fireproof pad of Example 2 59 Aerogel in the fireproof pad of Example 2 89.4 Silicone in the fireproof pad of Example 2 52.9 Non-combustible material 93.1

[0196] Referring to Table 3 above, it can be confirmed that the refractory pad of Example 2 has a residual rate of 50 wt% or more at 1000°C, and the aerogel within the refractory pad of Example 2 has a residual rate of 85% or more. In the case of the non-combustible material, the residual rate is lower than 100 wt%, but this is not because the non-combustible material was burned, but because the organic binder that holds the sheet shape of the non-combustible material was burned, resulting in a decrease in mass. In other words, the non-combustible material contained in the non-combustible material was maintained as is at 1000°C. Therefore, it can be expected that the fire resistance will be further improved when the non-combustible material is applied to the refractory pad of Example 2.

[0197]

[0198] Additionally, the thermal decomposition start temperature of each composition is shown in Table 4 below.

[0199] The starting temperature of thermal decomposition (℃) of Example 2 refractory pad 350 silicone 330 non-combustible material 363

[0200] Referring to Table 4 above, it can be confirmed that the thermal decomposition start temperature of the refractory pad of Example 2 is 300°C or higher.

[0201] In conclusion, referring to Tables 3 and 4 above, it can be confirmed that the refractory pad according to one embodiment of the present invention has excellent refractory properties even in a high-temperature environment, with a residual ratio of 50 wt% or more at 1000°C and a thermal decomposition start temperature of 300°C or more.

[0202]

[0203] As described above, the fireproof pad of the present invention includes a fireproof layer including a fireproof material and an insulating layer including a silicone-aerogel composite, and since the content of the aerogel of the silicone-aerogel composite satisfies 0.5 wt% or more and 40 wt% or less, it has low thermal conductivity, thereby exhibiting excellent insulation properties, and is easy to form into a pad, resulting in excellent processability.

[0204] Although the preferred embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto, and various modifications and improvements made by those skilled in the art using the basic concept of the present invention defined in the following claims also fall within the scope of the present invention.

[0205] [Explanation of symbols]

[0206] 1, 1-1, 1-2, 1-3: Fireproof pads

[0207] LL1: Insulation layer

[0208] LL2: Refractory layer

[0209] LL3: Adhesive layer

[0210] 10: 1st floor

[0211] 20: Second floor

[0212] 30: Third floor

[0213] 40: 4th floor

[0214] 50: Fifth floor

[0215] AG: Aerogel

[0216] SL: Silicone

Claims

1. Including an insulating layer comprising a silicone-aerogel composite including silicone and aerogel, The above silicone-aerogel composite is a fireproof pad containing aerogel in an amount of 0.5 wt% to 40 wt% based on the total weight of the insulation layer.

2. In paragraph 1, The above silicone-aerogel composite is a fire-resistant pad containing silicone in an amount of 60 wt% or more and 99.5 wt% or less based on the total weight of the insulation layer.

3. In paragraph 1, A fireproof pad having an aerogel content of 15 wt% or more and 30 wt% or less.

4. In paragraph 1, A fire-resistant pad having a thickness of the above insulation layer of 0.1 mm or more and 5 mm or less.

5. In paragraph 1, A fireproof pad further comprising a fireproof layer disposed on at least one surface of the insulating layer and comprising a fireproof material including at least one of a non-combustible material and a flame retardant material.

6. In paragraph 5, A refractory pad having a thickness of the refractory layer of 0.1 mm or more and 5 mm or less.

7. In paragraph 5, A fireproof pad in which the above fireproof layer is placed on both sides of the above insulation layer.

8. In paragraph 5, A refractory pad further comprising an adhesive layer disposed between the refractory layer and the insulating layer.

9. In paragraph 5, A fireproof pad wherein the refractory material comprises at least one of mica fiber, glass fiber, basalt fiber, ceramic paper, and vermiculite-coated glass fiber cloth.

10. In paragraph 5, comprising a first layer, a second layer, a third layer, a fourth layer, and a fifth layer laminated in sequence; The second layer and the fourth layer are the insulating layers, A refractory pad wherein the first layer, the third layer, and the fifth layer are refractory layers.

11. In paragraph 10, A refractory pad wherein the first layer and the fifth layer comprise the same refractory material, and the third layer comprises a refractory material different from the first layer and the fifth layer.

12. In paragraph 10, A refractory pad wherein the first layer, the third layer, and the fifth layer comprise the same refractory material.

13. In paragraph 10, A refractory pad wherein the first layer and the fifth layer are ceramic paper, and the third layer is glass fiber cloth coated with vermiculite.

14. In paragraph 10, A refractory pad wherein the first layer, the third layer, and the fifth layer are ceramic paper.

15. In paragraph 10, A refractory pad wherein the thicknesses of the second layer and the fourth layer are smaller than the thicknesses of the first layer, the third layer, and the fifth layer.

16. In paragraph 10, A refractory pad wherein the thickness of each of the first layer, the third layer, and the fifth layer is 0.5 mm or more and 3 mm or less.

17. In paragraph 10, A refractory pad, wherein the thickness of each of the second layer and the fourth layer is 0.1 mm or more and 2 mm or less.

18. In paragraph 1, The above aerogel is a refractory pad containing silica gel.

19. In paragraph 1, A refractory pad wherein the silicone comprises a poly(dimethyl siloxane) (PDMS) resin and optionally further comprises at least one of a crosslinking agent and a catalyst.

20. In paragraph 19, A refractory pad, wherein, based on the total mixing amount of the silicone-aerogel composite, the content of the polydimethylsiloxane resin is 47 wt% or more and 99.5 wt% or less, the content of the crosslinking agent is 0 wt% or more and 10 wt% or less, and the content of the catalyst is 0 wt% or more and 3 wt% or less.

21. In paragraph 1, A refractory pad having a thermal conductivity of 10 mW / m·K or more and 200 mW / m·K or less.

22. In paragraph 1, The above refractory pad is a refractory pad having a stress of 250 kPa or less at 40% strain.

23. In paragraph 1, The above refractory pad is a refractory pad having a residual rate of 50% by weight or more at 1000°C.

24. In paragraph 1, The above refractory pad is a refractory pad having a thermal decomposition start temperature of 300°C or higher.

25. In paragraph 1, The above refractory pad is a refractory pad having a combustion heat of 5000 cal / g or more.

26. In paragraph 1, The above refractory pad is a refractory pad having a thickness of 0.2 mm or more and 5 mm or less.

27. In paragraph 1, The above refractory pad is a refractory pad having a thickness reduction rate of 40% or less when a pressure of 220 kPa is applied.

28. In paragraph 1, The above refractory pad is a refractory pad having a thickness of 0.12 mm or more and 3 mm or less when a pressure of 220 kPa is applied.

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