Insulation element, method for producing an insulation element, and housing component having an insulation element

Abstract

The present invention relates to an insulation element (100), in particular for insulating housing components of energy stores or energy converters, for example for an electrically operated motor vehicle, the insulation element (100) comprising or being made of an insulation material (102), the insulation material (102) comprising or being made of at least one additive (104a, 104b), in particular for increasing a thermal and / or electrical and / or mechanical resistance of the insulation element (100). The invention also relates to a method for producing an insulation element (100).

Description

[0001] Insulating element, method for producing an insulating element and housing component with an insulating element

[0002] The present invention relates to an insulating element, a method for producing an insulating element and a housing component with an insulating element.

[0003] Housing components of energy storage devices or energy converters, particularly batteries, accumulators, or fuel cells, are subject to the risk of so-called thermal runaways (also known as thermal runaways). Thermal runaway generally refers to the overheating of an exothermic chemical reaction or a technical device due to a self-reinforcing heat-producing process. A runaway often leads to fire or explosion and, as a result, causes the device to be destroyed by excess pressure (bursting). For the sake of simplicity, the terms energy storage device and energy converter are used synonymously below; that is, the designs and advantages listed with reference to energy storage devices also apply analogously to energy converters, and vice versa.

[0004] It is therefore necessary to protect the housings of such energy storage devices from thermal penetration so that the spread to other components inside and / or outside the energy storage device can be prevented.

[0005] However, existing solutions are heavy, bulky, and sometimes have a complex multi-layer structure. Furthermore, such solutions often cannot provide complete protection.

[0006] The present invention is therefore based on the object of specifying an insulation element which offers reliable and at the same time simple protection, in particular against thermal and / or electrical penetration. The present invention is further based on the object of specifying a method for producing such an insulation element. With regard to the insulation element, the object is achieved according to the invention by an insulation element having the features of claim 1. With regard to the method, the object is achieved according to the invention by a method having the features of claim 9. Advantageous embodiments, further developments and variants are specified in the subclaims. The advantages and preferred embodiments listed with regard to the housing component are to be transferred analogously to the method and vice versa.

[0007] Specifically, the problem addressed by the insulation element is solved by an insulation element, in particular for insulating housing components of energy storage devices, for example, for an electrically powered motor vehicle, wherein the insulation element comprises or is formed from an insulation material. The insulation material serves, in particular, to prevent thermal and / or electrical breakdown of the housing component.

[0008] However, the application is not limited to housing components of energy storage devices, so that other components that require insulation of the type mentioned above can also be used.

[0009] The insulating material comprises or is formed from at least one additive. The additive serves in particular to increase the thermal and / or electrical and / or mechanical resistance of the insulating material.

[0010] This ensures reliable protection of the housing component without having to resort to the large-volume and complex insulation elements mentioned above, which also simplifies the overall structure of the housing component to be protected.

[0011] According to one embodiment, the insulation element comprises an insulating paper. Alternatively, the insulation element is designed as an insulating paper. The insulation material, together with the at least one additive, is preferably either applied to the insulating paper or incorporated into the insulating paper. By designing the insulation element as an insulating paper, a universal and user-friendly insulation element is created that is easy to process and versatile and adaptable to different types of housing components.

[0012] To achieve the thinnest possible insulation element compared to known solutions, the insulation element has a thickness in the range of 0.2 mm to 2 mm, preferably in the range of 0.5 mm to 1.5 mm, in particular 1 mm. The insulation element is thus thin enough to offer a simple and space-saving design, yet thick enough to meet the protection requirements.

[0013] It can be advantageous if the insulating element contains the insulating material completely or in part, or is formed completely or in part from the insulating material. In this case, for example, vulnerable areas of the housing component can be specially protected by the part of the insulating element that has the insulating material, while other areas of the housing component are protected by the insulating element alone. When the insulating element is completely applied or attached, at least all outer areas and sides of the housing component are preferably surrounded by the insulating element. In this context, it can alternatively also be provided that the housing component has several components, for example two components, which are both completely or partially provided with the insulating element and are, for example, joined together.

[0014] According to a preferred embodiment, the at least one additive comprises or is formed from an intumescent material.

[0015] For the purposes of this application, the term intumescent material refers to a material that increases in volume and correspondingly decreases in density when exposed to heat. For example, the intumescent material can form a foamed ash layer, which prevents the supply of oxygen and thus the spread of flames. Specifically, intumescent material forms a swollen layer in its activated state, i.e., upon heat input (such as during a thermal breakdown). This layer has a very low density but is resistant to thermal influences. Thus, in the event of a thermal breakdown, the intumescent material forms a heat-resistant protective layer, which particularly protects against the impact of abrasive particles at high temperatures, such as those generated during such a thermal breakdown.

[0016] In particular, the intumescent material is one of the following materials: water-based intumescent material, solvent-based intumescent material, or epoxy-based intumescent material.

[0017] A water-based intumescent material has the advantage of being environmentally friendly and cost-effective.

[0018] A solvent-based intumescent material, on the other hand, offers the advantage of a smooth finish, creating a particularly smooth and clean surface. A smooth and clean surface is important because dusty, porous, or rough surfaces increase the chances of thermal breakthrough and are therefore undesirable.

[0019] An epoxy-based intumescent material offers the advantage of being extremely durable and can therefore be used in harsh environments without reducing or losing its protective effect.

[0020] The thermal properties of intumescent materials, in particular, are determined specifically by their chemical composition. Particularly suitable intumescent materials contain, for example, a water-soluble alkali silicate binder. Such materials have, for example, a silica content of up to 96% and an N-octyl-2-pyrolidone content between 0.1% and 1%.

[0021] Alternatively or additionally, the at least one additive comprises or is formed from a thermal insulation material, in particular an aerogel. Such thermal insulation materials have low thermal conductivity and thus increase the thermal resistance of the insulation element and thus of the housing component. These materials are often also certified, so that they offer a guarantee of thermal resistance and can therefore, for example, correspond to and fulfill officially required standards. One such certificate or test is the UL94 flame test. By forming the additive as a thermal insulation material, the thermal protection of the insulation element can therefore be increased. In addition to the thermal protective effect of an aerogel, it also protects against electrical breakdown, so that the electrical resistance is also improved when using an aerogel.This additional advantage is based on the fact that good thermal conductors usually also exhibit good electrical conductivity. Consequently, in addition to their primary purpose as thermal insulators, they can also be used as electrical insulation materials.

[0022] Suitable aerogels include, for example, aerogels formed as hydrophilic and synthetic, highly amorphous silicate solids. Such aerogels have, for example, particle sizes in the range of 1 to 70 pm, preferably in the range of 1 to 20 pm, and especially in the range of 10 to 15 pm. Furthermore, these aerogels have pore sizes in the range of 1 to 50 nm, preferably in the range of 10 to 30 nm, and especially in the range of 15 to 25 nm. The thermal conductivity of such aerogels ranges between 0.025 and 0.03 W / (mK).

[0023] According to a further alternative or supplementary embodiment, the at least one additive comprises or is formed from a nonwoven fabric and / or fibers. Such fibers increase the mechanical structure of the insulation element and thus the protective effect against mechanical stress. Examples of such fibers can be AES wool, an insulating nonwoven fabric, glass fibers and / or metal fibers and / or metal alloy fibers and / or ceramic fibers.

[0024] To increase both the electrical and mechanical resistance of the insulating element, the additive can comprise or be formed from ceramic particles. This increases protection, for example, against AC / DC breakdown voltage.

[0025] Specifically, the problem addressed by the method is solved by a method for producing an insulation element. The method comprises the following steps:

[0026] Providing an insulating element; adding and / or applying an insulating material into or onto the insulating element;

[0027] Drying the insulation element

[0028] The insulation element is preferably provided in a space intended for coating.

[0029] When adding or applying the insulating material to or into the insulating element, known application methods can preferably be used. Such methods include, but are not limited to, spraying, galvanizing, powder coating, or thermal spraying. By applying known methods, the insulating element can be manufactured cost-effectively.

[0030] According to one embodiment of the method, the insulating material is added completely or partially to the insulating element and / or the insulating material is applied completely or partially to the insulating element. This achieves a customized protective capability of the insulating material, allowing the insulating element to be adapted to its use on the housing component.

[0031] Advantageously, at least one additive is added to the insulation material, or the insulation material is at least one additive. This configuration increases the protective effect of the insulation element.

[0032] Furthermore, within the scope of this application, a housing component is disclosed and claimed, in particular for an energy storage device, for example, for an electrically powered motor vehicle, wherein an insulating element is attached, in particular glued, to an inner side and / or an outer side of the housing component. The insulating element is, in particular, the insulating element already described.

[0033] The housing component can, in particular, be an energy storage device, for example, an energy storage device for an electrically powered motor vehicle. If the protective element forms at least part of the housing component, the housing component is preferably, but not restrictively, formed in multiple parts, so that at least part of the housing component is formed from the protective element. However, it is also conceivable for the entire housing component to be formed from the protective element, in particular to consist of the protective element.

[0034] Preferably, the insulation element is attached, in particular glued, completely or partially to the inside and / or the outside of the housing component.

[0035] Further preferred features and / or advantages of the invention are the subject of the following description and the drawings of exemplary embodiments.

[0036] The drawings show:

[0037] Fig. 1 is a schematic representation of an insulating element according to the invention according to a first embodiment with an insulating material that is completely embedded in the insulating element;

[0038] Fig. 2 is a schematic representation of an insulating element according to the invention according to a second embodiment with an insulating material that is partially embedded in the insulating element;

[0039] Fig. 3 is a schematic representation of an insulating element according to the invention according to a third embodiment with an insulating material that is completely applied to an upper side of the insulating element;

[0040] Fig. 4 is a schematic representation of an insulating element according to the invention according to a fourth embodiment with an insulating material that is applied in regions to an upper side of the insulating element;

[0041] Fig. 5 is a schematic representation of an insulating element according to the invention according to a fifth embodiment with an alternative insulating material that is completely embedded in the insulating element; Fig. 6 is a schematic representation of an insulating element according to the invention according to a sixth embodiment with an alternative insulating material that is partially embedded in the insulating element;

[0042] Fig. 7 is a schematic representation of an insulating element according to the invention according to a seventh embodiment with an insulating material that is completely applied to an upper side of the insulating element;

[0043] Fig. 8 is a schematic representation of an insulating element according to the invention according to an eighth embodiment with an insulating material that is applied in regions to an upper side of the insulating element;

[0044] Fig. 9 is a schematic representation of a housing component having an insulating element on an inner side and on an outer side;

[0045] Fig. 10 is a schematic representation of a block diagram of a method for producing an insulating element with an insulating material.

[0046] Identical or functionally equivalent elements are provided with the same reference numerals in all figures.

[0047] Referring to Fig. 1, a schematic representation of an insulation element 100 according to a first embodiment is shown. The insulation element 100 is preferably designed for a housing component and in particular for a housing component of an energy storage device, for example, for an electrically powered motor vehicle.

[0048] The insulation element 100 is preferably formed as insulation paper. It further comprises or is formed from an insulation material 102. The insulation material 102 serves in particular to increase the thermal and / or electrical and / or mechanical resistance of the insulation material 102 and thus also of the insulation element 100.

[0049] In the exemplary embodiment according to Fig. 1, the insulating material 102 is completely embedded in the insulating element 100. In other words, the insulating element 100 preferably has the same concentration of the insulating material 102 at every location. Alternatively, the concentration of the insulating material 102 can vary regionally within the insulating element 100.

[0050] To further increase the aforementioned resistance, the insulation element 100 further comprises an additive 104a, which, in the embodiment according to Fig. 1, is a thermal insulation material. This is graphically represented in Fig. 1 by the dotted pattern.

[0051] Aerogels, for example, have proven advantageous as suitable thermal insulation materials. Such materials can increase heat resistance by several hours.

[0052] Furthermore, the insulation element 100 can have an adhesive layer (not shown) on one or more outer sides, with which it is attached, in particular glued, to the housing component.

[0053] The insulation material 100 preferably has a thickness in the range of 0.2 mm to 2 mm, preferably in the range of 0.5 mm to 1.5 mm, in particular 1 mm. The insulation element 100 is therefore not shown to scale in the figures, but is shown greatly enlarged for better clarity of the features.

[0054] In the insulating element 100 schematically illustrated in Fig. 2 according to a second embodiment of the invention, the insulating material 102 is embedded only in certain regions, namely—as viewed in the image plane—in the left half of the insulating element 100. The right half, for example, comprises only the carrier material of the insulating element 100.

[0055] Similarly, the insulation element 100 according to Fig. 2 also additionally has the additive 104a only in the left-hand area, which is embedded in the insulation element 100 together with the insulation material 102.

[0056] This configuration allows, for example, the left-hand region of the insulation element 100 to offer special protection against thermal stress. Otherwise, the embodiment of an insulation element 100 shown in Fig. 2 corresponds in terms of structure and function to the embodiment shown in Fig. 1, so reference is made to the above description of the latter in this regard.

[0057] The third embodiment of the insulating element 100 according to the invention, schematically illustrated in Fig. 3, also comprises an insulating material 102. However, in contrast to the two previously described embodiments, this insulating material 102 is arranged on a top side 106 of the insulating element 100. In particular, the insulating material 102 is applied, for example, sprayed, to the top side 106 of the insulating element 100. In other words, the insulating material 102 is located only on or at the surface of the insulating element 100 in the manner of a layer.

[0058] Additionally, the insulating material 102 is completely applied to the upper side 106 of the insulating element 100, thus completely covering the surface of the insulating element 100. It goes without saying that the insulating material 102 can also be arranged, in particular applied, to an underside 108 of the insulating element 100 in an analogous manner, alternatively or additionally.

[0059] Furthermore, the insulation material 102 also has an additive 104a, which is applied in an analogous manner to the upper side 106.

[0060] Furthermore, the embodiment of an insulation element 100 shown in Fig. 3 corresponds in terms of structure and function to the embodiments shown in Figs. 1 and 2, so that reference is made to their above description in this respect.

[0061] Fig. 4 shows a schematic representation of an alternative, fourth embodiment to the third embodiment shown in Fig. 3.

[0062] Here, the insulating material 102 is arranged only in certain regions on the upper side 106 of the insulating element 100. Specifically, and viewed in the image plane, the insulating material 102 is arranged only in the left-hand region on the upper side 106 of the insulating element 100 and thus offers increased protection only there. Otherwise, the embodiment of an insulating element 100 shown in Fig. 4 corresponds in structure and function to the embodiments shown in Figs. 1 to 3, so that reference is made to their above description in this regard.

[0063] A fifth embodiment of the insulation element 100 according to the invention is shown schematically in Fig. 5.

[0064] In the fifth embodiment of the insulation element 100, the insulation material 102 is completely embedded in the insulation element 100, analogously to the first embodiment.

[0065] In other words, the insulation element 100 preferably has the same concentration of the insulation material 102 at every location.

[0066] However, the embodiment according to Fig. 5 has an alternative additive 104b, which is graphically represented by the striped pattern of the insulation element 100.

[0067] The additive 104b according to Fig. 5 comprises fibers, in particular glass fibers and / or metal fibers and / or metal alloy fibers and / or ceramic fibers. For example, silicate fibers are also conceivable, which have proven particularly suitable. The use of fibers as additive 104b particularly increases the mechanical resistance of the insulation material 102 and thus of the insulation element 100. If the fibers are ceramic fibers, they additionally increase the electrical resistance due to their electrically insulating nature.

[0068] Otherwise, the embodiment of an insulation element 100 shown in Fig. 5 corresponds in terms of structure and function to the embodiments shown in Figs. 1 to 4, so that reference is made to their above description in this respect.

[0069] In the insulating element 100 schematically illustrated in Fig. 6 according to a sixth embodiment of the invention, the insulating material 102 is embedded only in certain regions, namely—as viewed in the image plane—in the left half of the insulating element 100. The right half, for example, comprises only the carrier material of the insulating element 100.

[0070] Similarly, the insulation element 100 according to Fig. 6 also additionally has, only in the left-hand region, the additive 104b formed from the fibers described with reference to Fig. 5, which is embedded in the insulation element 100 together with the insulation material 102.

[0071] This design allows, for example, the left-hand area of ​​the insulation element 100 to offer special protection against mechanical stress.

[0072] Otherwise, the embodiment of an insulation element 100 shown in Fig. 6 corresponds in terms of structure and function to the embodiments shown in Figs. 1 to 5, so that reference is made to their above description in this respect.

[0073] The schematic representation in Fig. 7 shows a seventh embodiment of the insulation element 100 according to the invention.

[0074] The insulation element 100 also has an insulation material 102. However, as in the exemplary embodiment according to Fig. 3, this material is arranged on a top side 106 of the insulation element 100. In particular, the insulation material 102 is applied, for example, sprayed, to the top side 106 of the insulation element 100. In other words, the insulation material 102 is located only on or at the surface of the insulation element 100 in the manner of a layer.

[0075] Additionally, the insulating material 102 is completely applied to the upper side 106 of the insulating element 100, thus completely covering the surface of the insulating element 100. It goes without saying that the insulating material 102 can also be arranged, in particular applied, to an underside 108 of the insulating element 100 in an analogous manner, alternatively or additionally.

[0076] Furthermore, the insulation material 102 also comprises the fiber-formed additive 104b, which is applied in an analogous manner to the upper side 106. Otherwise, the embodiment of an insulation element 100 shown in Fig. 7 corresponds in terms of structure and function to the embodiments shown in Figs. 1 to 6, so that reference is made to their above description in this regard.

[0077] Fig. 8 shows a schematic representation of an alternative, eighth embodiment to the seventh embodiment shown in Fig. 7.

[0078] Here, the insulating material 102 is arranged only in certain regions on the upper side 106 of the insulating element 100. Specifically, and viewed in the image plane, the insulating material 102 is arranged only in the left-hand region on the upper side 106 of the insulating element 100 and thus preferably offers increased protection only there.

[0079] Otherwise, the embodiment of an insulation element 100 shown in Fig. 8 corresponds in terms of structure and function to the embodiments shown in Figs. 1 to 7, so that reference is made to their above description in this respect.

[0080] Fig. 9 shows a housing component 110, in particular for an energy storage device, for example for an electrically powered motor vehicle.

[0081] Alternatively, the housing component 110 can be an electrochemical cell, a battery cover or housing, a cell boundary, an intercellular boundary, or generally a module of the energy storage device. In other words, any component that is designed like a housing and is or can be part of an energy storage device can be considered a housing component 110.

[0082] The housing component 110 has, as shown in Fig. 9, an insulating element 100 on its outer side 112 and on its inner side 114. The insulating element 100 is, in particular, the insulating element 100 described above, so that reference is made to its above description in this regard.

[0083] Alternatively, however, the housing component 110 may have an insulating element 100 only on its outer side 112 or on its inner side 114. Thus, the housing component 110 is sufficiently protected in a simple yet reliable manner against thermal and / or electrical and / or mechanical stresses.

[0084] Fig. 10 shows in block diagram form the process sequences of a method for producing an insulation element 100.

[0085] In a first step 116 of the method, an insulating element 100 is provided. The insulating element 100 is preferably uncoated at this stage. In other words, the insulating element 100 does not yet have an insulating material 102 at this stage.

[0086] Provision is preferably made in a designated area, for example in a coating chamber.

[0087] In the second step 118 of the method, the insulating material 102 is added and / or applied into or onto the insulating element 100. When adding the insulating material 102 into the insulating element 100, the insulating material 102 is preferably introduced into the material of the insulating element 100. When applying the insulating material 102 to the insulating element 100, the insulating material 102 is preferably applied completely or in regions to a surface of the insulating element 100 in the manner of a protective layer.

[0088] In the third step 120 of the method, the insulating element 100 provided with the insulating material 102 is dried. Drying smoothes the surface of the insulating element 100, and specifically the insulating material 102, resulting in an abrasion-resistant surface that also reduces the adhesion of dirt particles. Since the adhesion of dirt particles, such as dust, leads to an increased risk of electrical breakdowns, a further advantage in terms of electrical protection can thus be achieved.

[0089] In further (not shown) embodiments of insulation elements 100, individual or multiple features and / or advantages of the aforementioned embodiments can be combined with one another as desired. For example, in the embodiment of an insulation element 100 shown in Fig. 1, an insulation material 102 with an alternative additive 104b can also be provided on the upper side 106 according to the seventh embodiment shown in Fig. 7.

[0090] List of reference symbols

[0091] Insulation element

[0092] Insulation material a,b additive

[0093] Top of the insulation element

[0094] Underside of the insulation element

[0095] Housing component

[0096] Outside of the housing component

[0097] Inside of the housing component

[0098] Providing an insulation element

[0099] Adding and / or applying an insulating material in or onto the insulating element

[0100] Drying the insulation element

Claims

Patent claims 1. Insulating element (100), in particular for insulating housing components of energy storage devices or energy converters, for example for an electrically operated motor vehicle, wherein the insulating element (100) comprises or is formed from an insulating material (102), wherein the insulating material (102) comprises or is formed from at least one additive (104a, 104b), in particular for increasing a thermal and / or electrical and / or mechanical resistance of the insulating element (100).

2. Insulating element (100) according to claim 1, wherein the insulating element (100) comprises an insulating paper or is designed as an insulating paper.

3. Insulation element (100) according to claim 1 or 2, characterized by a thickness with a value in the range of 0.2 mm to 2 mm, preferably in the range of 0.5 mm to 1.5 mm, in particular of 1 mm.

4. Insulating element (100) according to one of the preceding claims, wherein the insulating element (100) contains the insulating material (102) completely or in regions or is formed completely or in regions from the insulating material (102).

5. Insulation element (100) according to one of the preceding claims, wherein the at least one (104a, 104b) comprises or is formed from an intumescent material.

6. Insulation element (100) according to one of the preceding claims, wherein the at least one additive (104a, 104b) comprises or is formed from a thermal insulation material, in particular an aerogel.

7. Insulation element (100) according to one of the preceding claims, wherein the at least one additive (104a, 104b) comprises or is formed from a nonwoven and / or fibers.

8. Insulation element (100) according to one of the preceding claims, wherein the at least one additive (104a, 104b) comprises or is formed from ceramic particles.

9. A method for producing an insulation element (100), in particular according to one of claims 1 to 8, the method comprising the steps: Providing (116) an insulating element (100); Adding and / or applying (118) an insulating material (102) into or onto the insulating element (100); Drying (120) of the insulation element (100).

10. The method according to claim 9, wherein the insulating material (102) is added completely or partially to the insulating element (100) and / or the insulating material (102) is applied completely or partially to the insulating element (100).

11. The method according to claim 9, wherein at least one additive (104a, 104b) is added to the insulation material (102) or the insulation material (102) is at least one additive (104a, 104b).

12. Housing component (110), in particular for an energy storage device or an energy converter, for example for an electrically operated motor vehicle, wherein an insulation element (100), in particular according to one of the preceding claims, is attached, in particular glued, to an inner side (114) and / or an outer side (112) of the housing component (110).

13. Housing component (110) according to claim 12, wherein the insulation element (100) is attached, in particular glued, completely or partially to the inside (114) and / or the outside (112) of the housing component (110).

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