Gas protection element and system in a vehicle

Abstract

The gas protection element comprising an expandable material and a carrier element. The carrier element comprises a first flat side and an end face surrounding the first flat side. The end face substantially surrounds the entire first flat side. The expandable material is arranged on the first flat side of the carrier element. The expanded material, being the expandable material in an expanded state, is heat resistant. The gas protection element fulfils at least one of the following conditions: - the first flat side of the carrier element comprises at least one rip; - the expandable material is arranged on the end face of the carrier element.

Description

[0001] GAS PROTECTION ELEMENT AND SYSTEM IN A VEHICLE

[0002] The invention relates to a gas protection element and a system with the gas protection element, and in particular in an electrically driven motor vehicle.

[0003] In electric vehicles, in addition to the usual acoustic insulation, there is also the problem that an interior of the vehicle must be protected in case of a malfunction of the battery. When the battery of the electric vehicle goes through thermally crack up or overheats in an exothermic chemical reaction, toxic and very hot gases are produced. These toxic hot gases must be kept away from the passenger cabin of the vehicle for a minimum period, so that passengers in the vehicle can be brought to safety in good time. Nonsuited sealing elements are known from EP 2883781, US 2010 / 314813.

[0004] It is therefore an object of the present invention to provide a device which allows thermal toxic hot gases, which arise during a thermal failure of the battery of an electric vehicle, to be kept away from the passenger cabin.

[0005] The objective technical problem is solved by a gas protection element for sealing an opening in an electric vehicle to protect the passenger from gas. The electric vehicle e.g. electric car, is a passenger automobile that is powered by an electric motor, using energy stored in at least one on-board battery. Gas is released when the battery fails. The gas can be hot combustion gases created during battery failure. The electric vehicle can be a motor vehicle with an electric drive and an internal combustion engine (in particular in a hybrid vehicle) or an e-mobility vehicle with only an electric drive without and combustion engine.

[0006] The gas protection element comprising an expandable material and a carrier element. The carrier element comprises a first flat side and an end face surrounding the first flat side. In an embodiment, the end face substantially surrounds the entire first flat side. In other words, the end face is arranged around the first flat side in the circumferential manner.

[0007] The expandable material is arranged on the first flat side of the carrier element. This makes it possible to arrange the expandable material and / or the expanded material in a planar manner. The provision of the expandable material on the carrier element enables that the expanded material can be positioned more easily and accurately in the vehicle before expansion.

[0008] The expanded material, being the expandable material in an expanded state, is heat resistant, in particular the expanded material withstands heat of 500°C for at least 10 minutes.

[0009] In order to seal the cavity completely a high amount of foam is required, which leads to leads to sagging of the material prior to complete curing. To reduce the sagging, the gas protection element fulfils at least one of the following conditions:

[0010] - the first flat side of the carrier element comprises at least one rip;

[0011] - the expandable material is arranged on the end face of the carrier element.

[0012] The rip makes it possible to stabilize the expanded material after and / or during curing. Such a stabilization can ensure the gas protection, as the integrity of the expanded material is promoted by the stabilisation.

[0013] The expandable material arranged on the end face enables an additional sealing. The additional sealing at the end face improves the reliable sealing of the passenger cabin in the electrical vehicle. Accordingly, less expandable material must be used on the first flat side eventually, reducing the sagging of the expanded material and / or the expandable material. The reduction of sagging enables a more reliable sealing of the cavity and therefore a protection of the passengers in the electric vehicle.

[0014] The term flat side refers to the property of the carrier element to be a sheet like element. Nevertheless, the sheet like design of the carrier element is not restricted to a purely straight configuration of the carrier element. Accordingly, the carrier element and therefore the first flat side can also be bent in order to fit the opening to be sealed best. In an embodiment, the flat side of the carrier element is bent. The term flat side refers to the two-dimensional / areal expansion of the carrier element. It does not mean that the whole carrier element has to be planar, but it can be bent. In an embodiment, the carrier element comprises a first flat side and a second flat side, wherein the first and second flat sides are arranged opposite to each other in an essentially parallel manner. The end face is arranged between the first and second flat side. In other words, the end face connects the first and second flat side

[0015] In an embodiment, the expandable material is arranged substantially along the entire circumferential of the carrier element.

[0016] In an embodiment, the expanded material is in an expanded state and at least a partially cured epoxy resin composition. The already known materials can be used in the automotive industry to meet this new purpose. Epoxy-based compositions, which are expanded under the influence of heat, are often used to reinforce body sections. These materials have a very high mechanical strength in an expanded and cured state. Such materials are often referred to as reinforcing adhesives or "expanding reinforcer material", "reinforcer foam", "reinforcer material" or "expanding adhesives".

[0017] Thus, one advantage of the solution proposed here is that proven and well-known materials can be used to solve the objective problem. For example, automotive manufacturers do not need to release such materials again, which can save costs and effort.

[0018] In an embodiment, an area of the first flat side close to the end face is free of the rip. This reduces the overall weight of the gas protection element. The area of the first flat side close to the end face is an edge / fringe region of the first flat side.

[0019] In an embodiment, the carrier element comprises at least two rips, in particular at least three rips, arranged on the first flat side. In other words, the carrier element comprises a plurality of rips, in particular arranged on the first flat side. The rips make possible to improve the stabilisation of the expanded material and prevent extensive sagging.

[0020] In an embodiment, the rips are spaced by at least 20 mm, in particular by at least 50 mm. This increases the stabilisation of the expanded material and further reduces the sagging.

[0021] In an embodiment, the expandable material at the end face has a thickness of 1 mm to 15 mm, in particular 2 mm to 10 mm, in particular 3 mm to 4 mm. This can enable an improved overall sealing effect. The expandable material in the expanded state can be substantially arranged along the entire circumferential of the carrier element.

[0022] In an embodiment, the expanded material has a thickness from 1 mm to 50 mm, in particular 2 mm to 30 mm, in particular 5 mm to 20 mm. The layer thickness of the expanded material is measured substantially perpendicular to the first flat side of the carrier element.

[0023] Experiments have shown that the expanded material withstands the exposure to the hot gas for a sufficiently long time, e.g. ten minutes at 500°C, and therefore is heat resistant. In tests, a top surface layer of the hardened expanded material, in particular hardened epoxy resin composition, was charred / carbonized during exposure to the hot gas, but underlying layers of the hardened expanded material, in particular hardened epoxy resin composition, remained intact. The superficial carbonisation of the top surface layer is measures only 1 mm to 10 mm. Accordingly, a sufficiently thick layer must be provided to be able to withstand the load by the hot gas for a sufficiently long time.

[0024] In an embodiment, the expanded material prior to expansion, i.e. the expandable material, has a layer thickness measured perpendicular to the first flat side of the carrier element, of 1 mm to 10 mm. In particular, this layer thickness is 2 mm to 7 mm, in particular 3 mm to 6 mm.

[0025] In an embodiment, the rip is covered by the expandable material. This facilitates the application of the expandable material. In an alternative embodiment, the top edge of the rips is at least partially free of expandable material. The top edge of the rip is the far edge facing away from the carrier element. This improves the stability of the expandable material on the carrier element.

[0026] The invention further concerns a system, in particular a system for sealing an opening in an electrically driven motor vehicle, the system comprises an opening in a cavity of the vehicle. The opening connects a first region of the cavity with a second region of the cavity. The first region is facing towards a battery of the vehicle and the second region is facing away from the battery, in particular towards a passenger cabin of the vehicle. The term “the first region is facing towards a battery” might be understood as being in fluid communication towards the battery. In other words: The first region is air-permeable toward a battery of the motor vehicle, and the second region is air-permeable toward a passenger cell of the motor vehicle. The system further comprises a gas protection element as described in this text. The gas protection element is arranged in the opening, and in particular the gas protection element is sealing the opening. In other words, the gas protection element, in particular the expanded material closes the opening against the first region. The first flat side of the carrier element is arranged facing the first region of the cavity. Accordingly, in case of a failure of the battery hot and / or toxic gas is flowing towards the gas protection element facing the first flat side with the expanded material on first flat side of the carrier element. This enables the sealing of the opening with the help of the expanded material facing the hot and / or toxic gas originating from a battery failure.

[0027] In an embodiment, the at least part of the gas protection element is tilted in the vehicle with respect to the earth gravity by a tilting angle. A tilting angle of 0°, meaning no tilting, refers to a substantial vertical arrangement of the gas protection element in the vehicle with respect to earth gravity. The tilting of the of the gas protection element within the vehicle further reduces potential sagging as the force of the earth gravity is countered by the tilting, reducing the force in particular acting on the out most area of the expanded material. In an embodiment, at least part of the expanded material arranged on the first flat side is tilted by the tiling angle.

[0028] The gas protection element can also be called insulation element, as is seals / insulates an opening in the cavity.

[0029] The use of an expandable material enables simple and efficient seal of the opening. The gas protection element can be installed in the cavity in a non-expanded state and is then expanded and cured in an oven during the coating of the body. Thus, the handling, installation and planning of such gas protection elements is simple and cost-effective.

[0030] In connection with this invention, the term "insulating element" or "insulation" or "insulated" comprises elements or structures or process steps for sealing and / or sealing and / or insulation of an opening in the cavity of a vehicle. The different properties of such an insulating element can occur individually or in combination with each other.

[0031] In an embodiment, the tilting angle is 5° to 60°, in particular up to 30°, in particular up to 45°. Such a tilting of the carrier element improves the stability of the expanded material and reduces sagging. In an embodiment, the rip is arranged essentially horizontally. The horizontal arrangement refers to the earth gravity field in the installed state in the cavity of the vehicle. The horizontal rip supports the expanded material.

[0032] In an embodiment, the opening is channel-shaped. In an embodiment, the opening is formed by side walls surrounding a cavity. In an embodiment, the opening is formed as a hole. The opening can be formed in particular by an opening in a wall.

[0033] In an embodiment, only expanded material of the gas protection element is exposed to the first area. Such an arrangement of expanded material offers the advantage that the hardened expanded material, in particular the hardened epoxy resin composition, forms an effective protective shield against the toxic and hot gases coming from the failing battery. Experiments have shown that many other materials do not withstand such a load for a sufficiently long time. Thus, it is advantageous if only this resistant expanded material is exposed to the hot gas, and no other components of the insulating element (such as sections of a carrier or similar) are exposed to a hot gas flow.

[0034] Expandable material and Expanded material

[0035] In an installed state, meaning the gas protection element of the system sealing the opening in a finished vehicle, the originally expandable material is present as an expanded material. However, certain properties of this expanded material can be better described by a pre-expansion condition. Therefore, in this text reference is made to the expanded material after expansion, and to the expandable material before expansion.

[0036] In an embodiment, the expanded material has a volume between 50% and 1200% larger than before expansion. In particular, the volume increases by between 100% and 1000%, in particular between 200% and 800%.

[0037] In an embodiment, the expanded material is a foamed and cured epoxy composition. In an embodiment, the expanded material is obtained from a one-component heat-curing epoxy resin composition.

[0038] In an embodiment, the expandable material comprises a one-component heat-curing epoxy resin composition, comprising: a) at least one epoxy A with an average of more than one epoxy group per molecule; b) at least one latent hardener for epoxy resins; and c) at least one physical or chemical blowing agent BA.

[0039] In other words, the expanded material present before expansion as an expandable material contains the mentioned composition.

[0040] In an embodiment, the proportion of the epoxy resin A with an average of more than one epoxy group per molecule is 30% to 90% by weight, 35% - 85% by weight, 40% - 75% by weight, more preferably 45% - 60% by weight, based on the total weight of the heatcuring one-component epoxy resin composition.

[0041] In an embodiment, the epoxy resin A is a solid epoxy resin.

[0042] In an embodiment, the one-component heat-curing epoxy resin composition also comprises at least one toughness enhancer D.

[0043] In an embodiment, the toughness enhancer D is selected from the group consisting of terminal blocked polyurethane polymers DI, liquid rubbers D2 and core-shell polymers D3.

[0044] In an embodiment, the latent hardener is selected from dicyandiamide, guanamines, guanidins, aminoguanidins and derivatives thereof, substituted urea, imidazoles and amine complexes, in particular dicyandiamide. In an embodiment, the one-component heat-curing epoxy resin composition further comprises at least one filler F, selected from the group consisting of calcium carbonate, calcium oxide, talc, glass fibers, and fumed silica, preferred talc, glass fibers, and fumed silica.

[0045] In an embodiment, the one-component heat-curing epoxy resin composition further comprises at least one flame-retardant component G. In particular, the flame-retardant component G is selected from the list consisting of ammonium phosphate, ammonium pyrophosphate, ammonium polyphosphate, melamine phosphate, magnesium sulfate and boric acid, in particular ammonium polyphosphate. In particular, the ammonium polyphosphate can have a particle size of < 100 pm, in particular 50 pm - 5 pm.

[0046] The total proportion of the flame-retardant component G can be 3%-50% by weight, in particular 5%-40% by weight, in particular 8%-35% by weight, based on the total weight of the epoxy resin composition.

[0047] In an embodiment, the ammonium polyphosphate is an ammonium polyphosphate of formula (NH4PO3)n having n of 200 - 2000, in particular 600 - 1500.

[0048] In an embodiment, the proportion of the blowing agent BA is 0.1%- 10% by weight, preferably 0.5%-5% by weight, in particular l%-3% by weight, based on the total weight of the epoxy resin composition.

[0049] The epoxy resin composition is one component, which means that the components of the epoxy resin composition, in particular the epoxy resin and the hardener, are present as one component (in one phase) without curing at normal ambient or room temperature. It can therefore be handled in this mixed, one phase form. In contrast to that in two- component systems, the components can only be mixed immediately before application. Room temperature refers to a temperature of 23°C, unless otherwise indicated. In an embodiment, the one-component epoxy resin composition is cured by heating, typically at a temperature of more than 70°C, for example in the range of 100°C to 220°C.

[0050] The prefix "poly" in expressions such as polyol or polyisocyanate means that the compound has two or more of the groups mentioned. For example, a polyisocyanate is a compound with two or more isocyanate groups. The term "independent of each other" used below means that in the same molecule two or more similarly described substituents by definition may have the same or different meanings.

[0051] The dashed lines in the formulas in this document represent the bond between the respective substituent and the corresponding rest of the molecule.

[0052] In an embodiment, the heat-curing one-component epoxy resin composition contains at least one epoxy A with an average of more than one epoxy group per molecule. The epoxy group is in particular present as a glycidyl ether group.

[0053] The proportion of the epoxy resin A with an average of more than one epoxy group per molecule is in particular 30%-90% by weight, 35%-85% by weight, 40%-75 % by weight, especially preferably 45%-60% by weight, based on the total weight of the heatcuring one-component epoxy resin composition.

[0054] The epoxy resin A with an average of more than one epoxy group per molecule is in particular a liquid epoxy resin or a solid epoxy resin, in particular a solid epoxy resin. The term "solid epoxy resin" is very familiar to the skilled person in the field of epoxides and is used in contrast to "liquid epoxy resins". The glass transition temperature of solid resins is above room temperature, so that they can be crushed into free-flowing powders at room temperature. In particular, more than 70 wt .-%, more preferably more than 80 wt .-%, more than 90 wt .-%, more than 95 wt .-%, more than 98 wt .-% of the epoxy A is a solid epoxy resin, in particular epoxy resins have formula (II)

[0055] In this formula, the substituents R' and R" mean either H or CH3 independently of each other.

[0056] For solid epoxy resins, the index s has a value of > 1.5, in particular from 2 to 12. Such solid epoxy resins are commercially available, for example, from Dow or Huntsman or Hexion.

[0057] Compounds of formula (II) having an index s of 1 to 1.5 are referred to by the skilled person as semi-solid epoxy resins. For the purposes of the present invention, they are also considered solid resins. However, in particular solid epoxy resins are epoxy resins in the narrower sense, that is, in which the index s has a value > 1.5.

[0058] For liquid epoxy resins, the index s has a value less than 1. In particular, s has a value less than 0.2.

[0059] Therefore, it is preferably diglycidyl ethers of bisphenol A (DGEBA), bisphenol F and bisphenol A / F. Liquid resins of this type are available as Araldite® GY 250, Araldite® PY 304, Araldite® GY 282 (Huntsman) or THE™ 331 or THE™ 330 (Dow) or Epikote 828 (Hexion).

[0060] The epoxy resin A is in particular a solid epoxy resin of formula (II).

[0061] In an embodiment, the heat-curing one-component epoxy resin composition further comprises at least one latent hardener for epoxy resins. Latent hardeners are essentially inert at room temperature and are activated by increased temperature, typically at temperatures of 70°C or more, which initiates the curing reaction. The usual latent hardeners for epoxy resins can be used. A nitrogen-containing latent epoxy hardener can be preferred.

[0062] The latent hardener is in particular selected from dicyandiamide, guanamines, guanidins, aminoguanidins and derivatives thereof, substituted urea, imidazoles and amine complexes, preferably dicyandiamide.

[0063] The latent hardener is in particular used in stoichiometric amount based on the epoxy groups in the composition. The molar ratio of the epoxy groups to the active hydrogen of the latent hardener is in particular 0.8 to 1.2, in particular 0.9 to 1.1, in particular 0.95 to 1.05.

[0064] The proportion of the latent hardener is in particular 0.1% to 15% by weight, in particular 0.2% to 5% by weight, in particular 0.5 to 3% by weight, based on the total weight of the epoxy resin composition.

[0065] The one-component heat-curing epoxy resin composition optionally comprises at least one toughness enhancer, also called toughness improver D. The toughness enhancer D can be solid or liquid. In particular, the toughness enhancer D is selected from the group consisting of terminal blocked polyurethane polymers DI, liquid rubbers D2 and coreshell polymers D3.

[0066] The proportion of toughness improvers D is in particular 5%-30% by weight, in particular 7.5%-20 % by weight, based on the total weight of the epoxy resin composition.

[0067] In an embodiment, the one-component heat-curing epoxy resin composition further comprises at least one filler F. Preferably mica, talc, kaolin, wollastonite, feldspar, Syenite, chlorite, bentonite, montmorillonite, calcium carbonate (precipitated or ground), dolomite, quartz, silica (smoked or precipitated), cristobalite, calcium oxide, aluminium hydroxide, magnesium oxide, Ceramic hollow beads, glass hollow beads, organic hollow beads, glass beads, glass fibers and color pigments. In particular fillers are selected from the group consisting of calcium carbonate, calcium oxide, talc, glass fibers and pyrogenic silica, more preferably talc, glass fibers and pyrogenic silica.

[0068] In embodiments, the total proportion of the total filler F is advantageously 3%-50% by weight, in particular 5%-40% by weight, 8%-35% by weight, based on the total weight of the epoxy resin composition.

[0069] In an embodiment, the one-component heat-curing epoxy resin composition comprises at least one physical or chemical blowing agent BA.

[0070] Chemical blowing agents are organic or inorganic substances that form or cleave gaseous substances under the influence of temperature, humidity, electromagnetic radiation or chemicals. Such substances are, in particular, azodicarbonamides, sulfohydrazide, hydrogen carbonates or carbonates. Compounds can be used as physical blowing agents, which, for example, in the event of temperature, pressure or volume changes, in particular in the event of temperature increase, transition into the gaseous state of aggregation and thus form a foam structure by volume expansion. Such physical blowing agents are in particular liquids that evaporate at elevated temperature. In addition, gases or low boiling liquids can be used as physical blowing agents, which are introduced into the composition in microencapsulated form. Both chemical and physical blowing agents are capable of producing foam structures in polymer compositions.

[0071] In embodiments, the at least one physical or chemical blowing agent BA in particular has an activation temperature of 120°C to 220 C, in particular from 140 C to 200 C.

[0072] In an embodiment, the proportion of the blowing agent BA is 0.1wt%-10 wt .-%, in particular 0.5wt%-5 wt .-%, in particular lwt%-3 wt .-%, based on the total weight of the epoxy resin composition. In an embodiment, the one-component heat-curing epoxy resin composition comprises: 30 - 90 % by weight, 35 - 85 % by weight, 40 - 75 % by weight, in particular 45 - 60% by weight, based on the total weight of the heat-curing epoxy resin composition, of which at least one epoxy resin A has in the mean more than one epoxy group per molecule;

[0073] 0.1 to 15 % by weight, in particular 0.2 to 5 % by weight, in particular 0.5 to 3 % by weight, based on the total weight of the heat-curing epoxy resin composition, of at least one latent hardener for epoxy resins, more particularly dicyandiamide;

[0074] 0.1-10% by weight, in particular 0.5-5% by weight, in particular 1-3% by weight, based on the total weight of the heat-curing epoxy resin composition, the blowing agent BA; in particular 5 - 30% by weight, in particular 7.5 - 20% by weight of at least one toughness improver D, based on the total weight of the heat-curing epoxy resin composition; in particular 5-40% by weight, in particular 20-40% by weight, based on the total weight of the heat-curing epoxy resin composition, of a filler F selected from the group consisting of calcium carbonate, calcium oxide, talc, glass fibers and pyrogenic silica, in particular talc, glass fibers and pyrogenic silica;

[0075] Optionally 3-50% by weight, in particular 5-40% by weight, in particular 8-35% by weight, based on the total weight of the heat-curing epoxy resin composition, of at least one flame-retardant component G selected from the list consisting of ammonium phosphate, ammonium pyrophosphate, ammonium polyphosphate, melamine phosphate, magnesium sulfate and boric acid, in particular ammonium polyphosphate.

[0076] In an embodiment, it may be advantageous if in particular the one-component heat-curing epoxy resin composition to more than 80 wt .-%, in particular to more than 90 wt .-%, in particular to more than 95 wt .-%, in particular to more than 98 wt .-%, based on the total weight of the epoxy resin composition, consists of the aforementioned components. In an embodiment, the carrier element is designed as a foil. In particular, the carrier element is designed to be flexible. In an embodiment, the gas protection element may be made of metal.

[0077] In an alternative embodiment, the carrier element is formed as a rigid carrier. In an embodiment, the carrier element is made in particular of plastic.

[0078] In an embodiment, the carrier element and / or expandable material are produced by a two- component injection molding process.

[0079] In an embodiment, the gas protection element does not comprise a support also called carrier element. This offers the advantage that the gas protection element can be produced more cost-effectively, for example by means of an extrusion process.

[0080] In an embodiment, the gas protection element is attached to a structure of the opening by means of an adhesive film. This has the advantage that the expandable material can be positioned in the opening area before expansion. In an embodiment, the gas protection element can be attached to a structure of the opening by a push pin. This method also offers the advantage that the expandable material can be prefixed at a desired position in the region of the opening before expansion without support.

[0081] In an embodiment, the system is in a motor vehicle without an internal combustion engine. As explained above, e-vehicle face special requirements compared to well-known combustion engine driven vehicle because of different requirements and different risk potential.

[0082] In an alternative embodiment, the system is in a motor vehicle with an electric drive and an internal combustion engine (in particular in a hybrid vehicle). In the context of this invention, the term "battery of the vehicle" refers to a battery which is used to supply an electric drive with energy. It is not specifically a battery used to start an internal combustion engine.

[0083] In an embodiment, a gap is present between the opening and the expandable material once positioned in the opening. This prevents a damaging of the expandable material during positioning. In an embodiment, the gap is 1 mm to 10 mm, in particular 2 mm to 6 mm, in particular approximately 3 mm.

[0084] The features of the gas protection element and the system can be individually combined without limitations.

[0085] Details and advantages of the invention are described below with reference to embodiments and with reference to schematic drawings.

[0086] Fig. 1 an example of an opening in a cavity;

[0087] Fig. 2 a schematic example of an opening with a gas protection element arranged in the opening; and

[0088] Figures 3a to 4b. examples of systems with a gas protection element in the opening.

[0089] Fig. 1 shows an example of an opening 5 in a cavity 50 of an electrically driven vehicle, also called e-vehicle. In this case, the opening 5 connects a first region 51 of the cavity 50 with a second region 52 of the cavity 50. The first region 51 is facing towards a battery of the vehicle and the second region 52 is facing away from the battery, in particular towards a passenger cabin of the vehicle. In other words: The first region 51 is air- permeable toward a battery of the motor vehicle, and the second region 52 is air- permeable toward a passenger cell of the vehicle. In this embodiment, the opening 5 is formed as a channel-shaped opening, wherein side walls 6 surround a cavity 50. In addition, arrows indicate the direction in which hot and toxic gas, origination from a failing battery, will travel in the event of thermal leakage of the vehicle's battery. In Fig. 2, an opening 5 in an electrical vehicle is shown. In Fig. 2, however, this opening 5 is now sealed by a gas protection element 1, which might also be called insulating element. This gas protection element 1 thus prevents hot and toxic gases from spreading from the first area 51 to the second area 52. This is shown in this figure with a dashed and crossed-out arrow.

[0090] Exemplary and possible embodiments of such gas protection element 1 are now schematically and incomplete shown in the following figures. In this case, for each embodiment, the system 10 is shown once in a state before an expansion of the expandable material 2 and after the expansion of the expandable material 2. The systems 10 after expansion is the one with the expanded material 21.

[0091] In Figures 3a and 3b, a first exemplary system 10 is shown. In this embodiment, the opening 5 is again channel-shaped. The gas protection element 1 is positioned in the opening 5 in such a way that the expanded material 21 closes the opening. The expanded material is oriented toward the first region 51. In this embodiment, the gas protection element 1 comprises both expandable material 2 or expanded material 21 and a carrier element 3. In this embodiment, this carrier element 3 also has a clip, which simplifies positioning at the site of the opening. In Fig. 3a, a main opening direction 11 is drawn through the opening 5 through. In this embodiment, this main opening direction runs substantially parallel to the side walls 6.

[0092] The carrier element comprises two horizontal rips 4 which are supporting the expandable material 2 as well as the expanded material 21.

[0093] In Figures 4a and 4b another example of a system 10 with a sealed opening 5 is shown. In contrast to the embodiment of Figs. 3a and 3b, the expandable material 2 is arranged on an end face of the carrier element 3. The carrier element 3 comprises a first flat side 31 and an end face 32 surrounding the first flat side. The end face 32 substantially surrounds the entire first flat side 31. In other words, the end face is arranged around the first flat side in the circumferential manner. Accordingly, the expandable material 2 is circumferentially surrounding the carrier element 3. Before the expansion there is a gap between the expanded material 2 and the side wall 6 of the opening. In the expanded state, the expanded material 21 builds a seal and engages with the side wall 6 by filling the gap due to expansion.

[0094] The gap between the side wall and the expandable material is approximately 3 mm.

[0095] In the expanded state the expanded material 21 completely closes the opening 5 toward the first region 51. As a result, the sealing effect of the gas protection element 1 against hot and toxic gases is fully fulfilled.

[0096] Reference signs

[0097] 1 gas protection element 10 4 rip

[0098] 10 system 5 opening 2 expandable material 50 cavity

[0099] 21 expanded material 51 first region

[0100] 3 carrier element 52 second region

[0101] 31 first flat side 15 6 side wall

[0102] 32 end face

Claims

Claims1. Gas protection element 1 for sealing an opening in an electric vehicle to protect the passenger from gas, the gas protection element 1 comprising an expandable material 2 and a carrier element 3; wherein the carrier element 3 comprises a first flat side 31 and an end face 32 surrounding the first flat side 32, wherein the expandable material 2 is arranged on the first flat side 31 of the carrier element 3; wherein the expanded material 2’ is heat resistant; wherein the gas protection element fulfils at least one of the following conditions:- the first flat side 31 of the carrier element 3 comprises at least one rip 4;- the expandable material 3 is arranged on the end face 32 of the carrier element 3.

2. Gas protection element 1 according to claim 1, wherein the expanded material withstands heat of 500°C for at least 10 minutes.

3. Gas protection element 1 according to one of the previous claims, wherein expanded material 21 is in an expanded state and at least a partially cured epoxy resin composition.

4. Gas protection element 1 according to one of the previous claims, wherein an area of the first flat side close to the end face is free of the rip.

5. Gas protection element 1 according to one of the previous claims, wherein the carrier element comprises at least two rips, in particular at least three rips.

6. Gas protection element 1 according to claim 5, wherein the rips are spaced by at least 20 mm, in particular by at least 50 mm.

7. Gas protection element 1 according to one of the previous claims, wherein the expandable material at the end face has a thickness of 1 mm to 15 mm, in particular 2 mm to 10 mm, in particular 3 mm to 4 mm.

8. Gas protection element 1 according to one of the previous claims, wherein the expanded material 21 has a thickness from 1 mm to 50 mm.

9. Gas protection element 1 according to one of the previous claims, wherein the rip 4 is covered by the expandable material 2.

10. Gas protection element 1 according to one of the previous claims, the gas protection element fulfils at both of the following conditions:- the first flat side 31 of the carrier element 3 comprises at least one rip 4;- the expandable material 3 is arranged on the end face 32 of the carrier element 3.

11. System 10 for sealing an opening 5 in an electrically driven motor vehicle, the system 10 comprising: an opening 5 in a cavity 50 of the vehicle, wherein the opening 5 connects a first region 51 of the cavity 50 with a second region 52 of the cavity 50; wherein the first region 51 is facing towards a battery of the vehicle and the second region 52 is facing away from the battery; the system further comprises a gas protection element 1 according to any of the previous claims; wherein in the gas protection element 1 is arranged in the opening 5, and wherein the first flat side 31 of the carrier element 3 is arranged facing the first region 51 of the cavity 50.

12. System 10 according to claim 11, wherein the gas protection element 1 is tilted in the vehicle with respect to the earth gravity by a tilting angle.

13. System 10 according to claim 12, wherein the tilting angle is 5° to 60°, in particular up to 30°, in particular up to 45°.

14. System 10 according to any one of claims 11-13, wherein the rip 4 is arranged essentially horizontally.

15. System 10 according to any one of claims 11-14, wherein only expanded material 21 of the gas protection element 1 is exposed to the first region 51.

16. System 10 according to any one of claims 11-15, wherein the expandable material2 comprises the following composition: one-component heat-curing epoxy resin composition, comprising: a) at least one epoxy A with an average of more than one epoxy group per molecule; b) at least one latent hardener for epoxy resins; and c) at least one physical or chemical blowing agent BA.

17. System 10 according to any one of claims 11-16, wherein agap is present between the opening 5 and the expandable material 2 once positioned in the opening 5.

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