Fireproof pad and manufacturing method thereof

Abstract

A method for manufacturing a fireproof pad according to the present invention comprises the steps of: (A) mixing a solvent-free liquid silicone and an aerogel to form a solid silicone-aerogel composite; and (B) continuously sheeting the silicone-aerogel composite by means of a hot roll press to form a thermal insulation layer, wherein the content of the aerogel is 0.5-40 wt% on the basis the total weight of the silicone-aerogel composite.

Description

Fireproof pad and method of manufacturing the same

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

[0002] The present application claims the benefit of priority based on Korean Patent Application No. 10-2025-0035592 filed March 19, 2025 and Korean Patent Application No. 10-2026-0038101 filed March 3, 2026, and all contents disclosed in the documents of said Korean patent applications are incorporated herein as part of the specification.

[0003] The present invention relates to a fireproof pad and a method for manufacturing the same, and more specifically, to a fireproof pad comprising a silicone-aerogel composite and a method for manufacturing the same.

[0004] As technology development 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 interest as an energy source not only for mobile devices such as mobile phones, digital cameras, laptops, and wearable devices, but also for power devices such as electric bicycles, electric vehicles, and hybrid electric vehicles.

[0005] A secondary battery cell is manufactured by embedding an electrode assembly together with an electrolyte into a secondary battery case, and the electrode assembly is manufactured by stacking and / or winding a positive electrode, a separator, and a negative electrode. Multiple manufactured battery cells are stacked to form a battery module or a battery pack.

[0006] Depending on the operation of the cell, heat may be generated within the battery cell, and if this heat is transferred to adjacent cells and accumulates, battery thermal propagation occurs.

[0007] To prevent these problems, fire-resistant pads can be placed between battery cells to disperse the heat generated from the cells and prevent ignition inside the battery pack.

[0008] Currently, the industry manufactures fire-resistant pads using at least one material among silicone, polyurethane, and aerogel.

[0009] Figure 1 illustrates one step of a conventional method for manufacturing a fireproof pad.

[0010] Referring to FIG. 1, in the past, to manufacture a fireproof pad, a fireproof material (11C), an insulating material (10C), and a fireproof material (12C) were laminated in sequence in a mold (MD), and then hot-pressed (HP) to perform lamination and heat curing simultaneously to manufacture the fireproof pad. The insulating material (10C) is a mixture of at least one material selected from silicone, polyurethane, and aerogel, and is provided in powder form. Accordingly, the insulating material (10C) is provided by dispersing it evenly onto the fireproof material (11C) through manual work. However, since the insulating material (10C) has a low density and is easily blown away, it was difficult to provide it with a uniform thickness, and in particular, there was a limit to reducing the thickness error to the hundreds of micrometers unit through manual work.

[0011] In addition, since the insulating material (10C) must be manually dispersed inside the mold (MD) every time a fireproof pad is produced, continuous production of fireproof pads is impossible, and there were difficulties in applying it to the mass production process.

[0012]

[0013] Therefore, research is continuing on a method for manufacturing refractory pads that enables a continuous process with a uniform thickness range while solving the above-mentioned problems.

[0014] The present invention aims to solve the above-mentioned problem by providing a method for manufacturing a refractory pad that can continuously produce an insulating layer within a uniform thickness range by hot-roll pressing a silicone-aerogel composite.

[0015] In addition, a fire-resistant pad having a uniform thickness range can be provided, manufactured by the above-described method for manufacturing a fire-resistant pad.

[0016] The method for manufacturing a fireproof pad according to the present invention comprises: (A) a step of mixing solvent-free liquid silicone and aerogel to form a solid silicone-aerogel composite; and (B) a step of continuously sheeting the silicone-aerogel composite using a hot roll press to form an insulating layer; wherein, based on the total weight of the silicone-aerogel composite, the content of the aerogel is 0.5% by weight or more and 40% by weight or less.

[0017] In one embodiment, in step (B), the hot roll press may include two facing rolls, the gap between the two rolls may be 0.5 mm or more and 10 mm or less, and the pressure of the hot roll press may be 10 kPa or more and 1000 kPa or less.

[0018] In one embodiment, in step (B), the heating temperature of the hot roll press may be 50°C or higher and 150°C or lower.

[0019] In one embodiment, in step (B), the speed of the hot roll press may be greater than 0 mm / s and less than or equal to 100 mm / s.

[0020] In one embodiment, the average thickness of the insulation layer may be 0.5 mm or more and 10 mm or less, and the thickness deviation may be 20% or less.

[0021] In one embodiment, the hot roll press includes two facing rolls, and a pattern is formed on the surface of the two rolls, and in step (B), the pattern may be formed on the surface of the insulating layer.

[0022] In one embodiment, step (B) may include the step of providing a pattern film between the hot roll press and the silicone-aerogel composite and the step of continuously sheeting the silicone-aerogel composite with a hot roll press to form an insulating layer having a pattern of the pattern film formed on its surface.

[0023] In one embodiment, after step (B), the step of further heat-curing the insulation layer may be further included.

[0024] In one embodiment, based on the total weight of the silicone-aerogel composite, the silicone content may be 60 weight% or more and 99.5 weight% or less.

[0025] In one embodiment, the method may further include: (C) a step of forming a laminate by sequentially providing an adhesive layer containing an adhesive material and a refractory layer containing a refractory material on at least one surface of the insulating layer; and (D) a step of forming a refractory pad by laminating the laminate using a hot roll press.

[0026] In one embodiment, in step (D), forming the refractory pad may involve further heat-curing the laminate after hot roll pressing.

[0027] In one embodiment, the adhesive material may include at least one of a silicone-based adhesive material, an acrylic-based adhesive material, and an epoxy-based adhesive material.

[0028] In one embodiment, the refractory material may include at least one of mica fiber, glass fiber, basalt fiber, ceramic paper, and aramid fiber.

[0029] In one embodiment, the adhesive layer may be cured by providing the adhesive material via a slot die or spray process.

[0030] In one embodiment, the aerogel may contain SiO2, the particle size of the aerogel may be 0.01 mm to 1.5 mm, and the average diameter of the pores of the aerogel may be 1 nm to 200 nm.

[0031] In one embodiment, the silicone comprises a polydimethylsiloxane-based resin and may optionally further comprise at least one of a crosslinking agent and a catalyst.

[0032] In one embodiment, based on the total weight of the silicone-aerogel composite, the content of the polydimethylsiloxane-based resin may be 47% by weight or more and 99.5% by weight or less, the content of the crosslinking agent may be 0% by weight or more and 10% by weight or less, and the content of the catalyst may be 0% by weight or more and 3% by weight or less.

[0033] The fireproof pad of the present invention comprises an insulating layer comprising a silicone-aerogel composite including silicone and aerogel, wherein the average thickness of the insulating layer is 0.5 mm or more and 10 mm or less, the thickness deviation is 20% or less, and the content of the aerogel is 0.5 weight% or more and 40 weight% or less based on the total weight of the silicone-aerogel composite.

[0034] In one embodiment, it may further include a refractory layer provided on at least one surface of the insulating layer; and an adhesive layer disposed between the insulating layer and the refractory layer.

[0035] The present invention can provide a method for manufacturing a refractory pad that can continuously produce an insulating layer with a uniform thickness range using a hot roll press method.

[0036] The present invention can provide a fireproof pad having excellent thermal insulation, heat resistance, and fire resistance, and a uniform thickness range.

[0037] Figure 1 illustrates one step of a conventional method for manufacturing a fireproof pad.

[0038] Figure 2 illustrates a flowchart of the method for manufacturing a fire-resistant pad according to the present invention.

[0039] Figure 3 illustrates one step of the method for manufacturing a fireproof pad of the present invention.

[0040] Figure 4 shows an enlarged view of a portion of Figure 3.

[0041] Figure 5 illustrates one step of the method for manufacturing a fireproof pad of the present invention.

[0042] Figure 6 illustrates one step of the method for manufacturing a fireproof pad of the present invention.

[0043] FIG. 7 illustrates one step of the method for manufacturing a fireproof pad of the present invention.

[0044] FIG. 8 illustrates one embodiment of the fire-resistant pad of the present invention.

[0045] FIG. 9 illustrates one embodiment of the fire-resistant pad of the present invention.

[0046] FIG. 10 illustrates one embodiment of the fire-resistant pad of the present invention.

[0047] Figure 11 shows a photograph of the insulation layer prepared in Example 1.

[0048] 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 present invention. The present invention may be embodied in various different forms and is not limited to the embodiments described herein.

[0049] To clearly explain the present invention, parts unrelated to the explanation have been omitted, and the same reference numerals are used for identical or similar components throughout the specification.

[0050] Furthermore, the size and thickness of each component shown in the drawings are depicted arbitrarily for convenience of explanation, and thus the present invention is not necessarily limited to what is illustrated. Thicknesses have been enlarged in the drawings to clearly represent various layers and regions. Additionally, for convenience of explanation, the thickness of some layers and regions in the drawings has been exaggerated.

[0051] Furthermore, when a part such as a layer, membrane, region, or plate is said to be "on" or "on" another part, this includes not only cases where it is "immediately above" another part, but also cases where there is another part in between. When a part is said to be "immediately above" another part, it means that there is no other part in between. Also, saying that a part is "on" or "on" a reference part means that it is located above or below the reference part, and does not necessarily mean that it is located "on" or "on" facing the opposite direction of gravity.

[0052] Furthermore, throughout the specification, when a part is described as “comprising” a certain component, this means that, unless specifically stated otherwise, it does not exclude other components but may include additional components.

[0053]

[0054] With reference to FIGS. 2 to 10, the method for manufacturing a fireproof pad of the present invention and the fireproof pad of the present invention will be described below.

[0055]

[0056] The method for manufacturing a fire-resistant pad according to the present invention is,

[0057] (A) A step of forming a solid silicone-aerogel composite by mixing solvent-free liquid silicone and aerogel; and

[0058] (B) A step of continuously sheeting the above silicone-aerogel composite using a hot roll press to form an insulating layer; comprising,

[0059] Based on the total weight of the above silicone-aerogel composite, the content of the aerogel is 0.5 weight% or more and 40 weight% or less.

[0060]

[0061] Figure 2 illustrates a flowchart of the method for manufacturing a fire-resistant pad according to the present invention.

[0062] Referring to FIG. 2, the method for manufacturing a fire-resistant pad according to the present invention comprises: (A) a step of forming a silicone-aerogel composite (S10); and (B) a step of forming an insulating layer by hot-roll pressing the silicone-aerogel composite (S20). Additionally, the method may further include: (C) a step of forming a laminate by sequentially providing an adhesive layer and a fire-resistant layer on at least one surface of the insulating layer (S30); and (D) a step of forming a fire-resistant pad by hot-roll pressing the laminate (S40).

[0063] Specifically, (A) the step of forming a silicone-aerogel composite (S10) is a step of forming a solid silicone-aerogel composite by mixing solvent-free liquid silicone and aerogel. At this time, based on the total weight of the silicone-aerogel composite, the content of the aerogel may be 0.5 wt% or more and 40 wt% or less, preferably 0.5 wt% or more and 30 wt% or less, more preferably 10 wt% or more and 30 wt% or less. If the content of the aerogel is less than 0.5 wt%, the thermal insulation properties of the silicone-aerogel composite may be reduced. In addition, if the content of the aerogel exceeds 40 wt%, the silicone content is relatively reduced, making it difficult to form the silicone-aerogel composite. Consequently, the bonding strength between particles is reduced, and sufficient compression and integration are not achieved during the hot roll press process, making it difficult to form a pad-shaped sheet.

[0064] The solvent-free liquid silicone comprises a poly(dimethyl siloxane), hereinafter PDMS resin, and optionally may further comprise at least one of a crosslinking agent and a catalyst.

[0065] Specifically, the PDMS resin has a siloxane backbone and is a PDMS resin having vinyl groups at the ends (poly(dimethyl siloxane)-vinyl terminated, ViMe2SiO(Me2SiO) X It may be SiMe2Vi). However, the examples of PDMS resins are not limited to this, and materials that are thermosetting based on PDMS may be used. For example, peroxide-curable silicone or room temperature vulcanization (RTV) silicone may be used.

[0066] The molecular weight of the PDMS resin used in one embodiment may be 1,000 g / mol or more and 100,000 g / mol or less.

[0067] Silicon-based crosslinking agents containing at least one Si-H structure may be used as crosslinking agents. For example, Polymethylhydrogensiloxane (Me3SiO(MeHSiO) X SiMe3) can be used. During the thermal curing of silicon, the vinyl groups at the PDMS ends can react with the Si-H of the crosslinking agent to proceed with the thermal curing.

[0068] As a catalyst, a platinum catalyst may be used, or a peroxide-based initiator may be used depending on the curing mechanism.

[0069] In one embodiment, the composition of the silicon may include a PDMS resin and a crosslinking agent, a PDMS resin and a catalyst, or a PDMS resin, a crosslinking agent, and a catalyst.

[0070] Based on the total weight of the silicone-aerogel composite, the content of the PDMS resin may be 47% by weight or more and 99.5% by weight or less, the content of the crosslinking agent may be 0% by weight or more and 10% by weight or less, and the content of the catalyst may be 0% by weight or more and 3% by weight or less.

[0071] Aerogel is a porous material containing pores, and generally may include organic aerogel, inorganic aerogel, or a combination thereof, but the aerogel used in the present invention includes inorganic aerogel. For example, the aerogel may include silica (SiO2), alumina (Al2O3), or other metal oxides, and in one example, the aerogel may be silica gel.

[0072] In addition, the particle size of the aerogel may be approximately 0.01 mm or more and 1.5 mm or less, 0.05 mm or more and 1.5 mm or less, or 0.1 mm or more and 1.2 mm or less, but the examples are not limited thereto.

[0073] In one embodiment, the average diameter of the pores of the aerogel may be 1 nm or more and 200 nm or less, 1 nm or more and 100 nm or less, 1 nm or more and 50 nm or less, 10 nm or more and 30 nm or less, or 10 nm or more and 20 nm or less, but the embodiments are not limited thereto.

[0074] In one embodiment, the bulk density of the aerogel is 10 kg / m³ 3 100kg / m² or more 3 Below, 50 kg / m² 3 100kg / m² or more 3 Below, 70 kg / m² 3 100kg / m² or more 3 Less than or equal to 75 kg / m² 3 95 kg / m² or more 3 The following may be true, but the embodiments are not limited thereto.

[0075] In one embodiment, the aerogel may have a thermal conductivity of 50 mW / m·K or less, 40 mW / m·K or less, 30 mW / m·K or less, 20 mW / m·K or less, or greater than 0 mW / m·K and less than or equal to 15 mW / m·K, but the embodiments are not limited thereto. As the aerogel has such low thermal conductivity, the silicone-aerogel composite can exhibit excellent thermal insulation properties.

[0076] The silicone-aerogel of the present invention may have thermal insulation properties by including the aerogel as described above. For example, the thermal conductivity of the silicone-aerogel composite may be 10 mW / m·K or higher and 300 mW / m·K or lower.

[0077] In one embodiment, based on the total mass of the silicone-aerogel composite, the silicone content may be 60 weight% or more and 99.5 weight% or less, preferably 70 weight% to 99.5 weight%, and more preferably 70 weight% to 90 weight%.

[0078] (A) In step, the solvent-free liquid silicone is encapsulated by an aerogel with a high specific surface area, thereby forming a solid silicone-aerogel composite.

[0079] That is, step (A) involves mixing silicone and aerogel using a solvent-free method to form a solid silicone-aerogel composite. Compared to the wet manufacturing process of the aerogel composite, the process for removing the solvent is omitted, which simplifies the process and reduces processing time and costs, thereby facilitating the mass production of refractory pads.

[0080] The silicone-aerogel composite satisfies the above silicone and aerogel content, exhibits excellent thermal insulation properties, and can be applied as a fireproof pad as sheet formation proceeds easily.

[0081] Meanwhile, since only the mixing process is performed in step (A), the silicone-aerogel composite may exist in the form of a dispersed powder.

[0082]

[0083] Figure 3 illustrates one step of the method for manufacturing a fireproof pad of the present invention.

[0084] Figure 4 is an enlarged view of the AA region, which is part of Figure 3.

[0085] Referring to FIG. 3 and FIG. 4 together, (B) the step of forming an insulating layer by hot roll pressing the silicone-aerogel composite (S20) is the step of forming an insulating layer by sheeting the silicone-aerogel composite (CM) manufactured in step (A) using a hot roll press (RP).

[0086] The silicone-aerogel composite (CM) existing in powder form is sheeted into an insulating layer (10) through step (B). Specifically, the silicone-aerogel composite (CM) contained in the main body (BD) is continuously sheeted through a hot roll press (RP) to produce an insulating layer (10).

[0087] In one embodiment, the heating temperature of the hot roll press (RP) may be 50°C or higher and 150°C or lower, preferably 70°C or higher and 150°C or lower, more preferably 100°C or higher and 150°C or lower, and the speed may be greater than 0 mm / s and less than 100 mm / s, preferably greater than 1 mm / s and less than 100 mm / s, more preferably greater than 10 mm / s and less than 50 mm / s. When the above temperature and speed ranges are satisfied, the silicone-aerogel composite (CM) is sufficiently cured.

[0088] The thickness of the insulation layer (10) can be controlled by adjusting the gap (WD) between two opposing rolls (RL1, RL2) of a hot roll press (RP). In one embodiment, the gap (WD) between the two rolls (RL1, RL2) may be 0.5 mm or more and 10 mm or less. Additionally, the pressure of the hot roll press (RP) may be 10 kPa or more and 1000 kPa or less. As described above, the thickness of the insulation layer (10) can be controlled by adjusting the gap (WD) and pressure of the hot roll press (RP). For example, the thickness of the insulation layer (10) may be 0.5 mm or more and 10 mm or less, and preferably 0.5 mm or more and 3 mm or less.

[0089] As described above, the present invention uses a hot roll press (RP) to manufacture an insulating layer (10), in contrast to using a conventional press (HP, see FIG. 1). Accordingly, the silicone-aerogel composite (CM) provided in powder form can be sheeted independently without the support of a refractory material (11C, 12C), and continuous manufacturing of the insulating layer (10) is possible. In addition, by adjusting the spacing and pressure of the hot roll press (RP), the insulating layer (10) can be mass-produced within a certain thickness range.

[0090] In addition, it is possible to modify the shape of the hot roll press (RP). FIG. 4 illustrates an embodiment in which the two rolls (RL1, RL2) included in the hot roll press (RP) are plain, but is not limited thereto and patterns can be formed on the two rolls (RL1, RL2). For example, patterns such as triangles, right angles, straight lines, diagonals, and curves can be formed on the surface of the rolls (RL1, RL2). Accordingly, a pattern can be formed on the surface of the insulation layer (10).

[0091]

[0092] Figure 5 illustrates one step of the method for manufacturing a fireproof pad of the present invention.

[0093] Referring to FIG. 5, a pattern can be formed on the surface of two rolls (RL1', RL2') included in a hot roll press (RP'). As an example, the pattern is illustrated as having triangular irregularities, but the embodiment is not limited thereto.

[0094] Accordingly, a triangular pattern (PT) is formed on both sides of the manufactured insulation layer (10'). The thickness of the insulation layer (10') with the pattern (PT) formed in this way is measured as the average thickness. The insulation layer (10') may have an average thickness of 0.5 mm or more and 10 mm or less, and preferably 0.5 mm or more and 3 mm or less. In addition, the thickness variation of the insulation layer (10') may be 20% or less, which means that the difference between the thickness of the thickest part and the thickness of the thinnest part of the insulation layer (10') is 20% or less of the average thickness.

[0095] Meanwhile, FIG. 5 illustrates an embodiment in which irregularities are formed on the surfaces of each of the two rolls (RL1', RL2'), but is not limited thereto and irregularities may be formed on the surface of only one of the two rolls (RL1', RL2'). In this case, a pattern (PT) may be formed on only one side of the insulation layer (10') and the other side may be plain.

[0096]

[0097] Figure 6 illustrates one step of the method for manufacturing a fireproof pad of the present invention.

[0098] Referring to FIG. 6, the above step (B) may include the step of providing a pattern film between a hot roll press and a silicone-aerogel composite (hereinafter defined as step (B)-1) and the step of continuously sheeting the silicone-aerogel composite with a hot roll press to form an insulating layer on the surface having the pattern of the pattern film formed thereon (hereinafter defined as step (B)-2).

[0099] Referring to FIG. 6, step (B)-1 is a step of providing a pattern film (FL) between rolls (RL1, RL2) included in a hot roll press (RP) and a silicone-aerogel composite (CM). Specifically, the pattern film (FL) may include a first pattern film (FL1) provided between roll (RL1) and the silicone-aerogel composite (CM) and a second pattern film (FL2) provided between roll (RL2) and the silicone-aerogel composite (CM). However, not limited to FIG. 6, the pattern film (FL) may include only one of the first pattern film (FL1) and the second pattern film (FL2).

[0100] In one embodiment, the pattern film (FL) may be made of materials such as polyethylene terephthalate (PET), polytetrafluoroethylene (PTFE), polypropylene (PP), or polyethylene (PE).

[0101] Meanwhile, in FIG. 6, the pattern film (FL) is shown as having square-shaped irregularities, but the shape of the pattern is not limited to this.

[0102] (B)-2 is a step of forming an insulating layer (10'') on which a pattern of a pattern film (FL) is formed on the surface by continuously sheeting the silicone-aerogel composite using a hot roll press. By using the pattern film (FL) in this way, a pattern can be easily formed on the surface of the insulating layer (10'') without changing the shape of the rolls (RL1, RL2) included in the hot roll press (RP).

[0103]

[0104] A method for manufacturing a fireproof pad according to one embodiment may further include a step of additionally heat-curing the insulation layer after step (B). The additional heat-curing step is intended to complement the curing process of the insulation layer performed in step (B). This step may be performed selectively considering the thickness of the insulation layer. For example, if the thickness of the insulation layer becomes close to 10 mm, the additional heat-curing step of the insulation layer may be performed after step (B) to sufficiently transfer heat to the interior of the insulation layer and cure it.

[0105] For the additional heat curing step, methods such as placing the insulation layer in an oven or having the insulation layer placed on a conveyor belt pass through a heat curing furnace may be used. For example, the insulation layer may be additionally heat cured in an oven at a temperature of 100°C or higher and 150°C or lower for 30 seconds to 20 minutes. Alternatively, the insulation layer may be placed on a conveyor belt and pass through a heat curing furnace at a temperature of 100°C or higher and 150°C or lower. In this case, the speed of the conveyor belt may be the same as the speed of the hot roll press, for example, the speed may be greater than 0 mm / s and less than or equal to 100 mm / s. However, the embodiments are not limited thereto, and other conditions or known heat curing methods may be used.

[0106]

[0107] As described above, the method for manufacturing a fireproof pad according to the present invention comprises (A) a step of forming a silicone-aerogel composite (S10), and (B) a step of forming an insulating layer by hot roll pressing the silicone-aerogel composite (S20), and by controlling the content of the aerogel to be 0.5% by weight or more and 40% by weight or less based on the total weight of the silicone-aerogel composite, the method for manufacturing a fireproof pad can be provided such that the insulating layer (10) can be continuously mass-produced in a uniform thickness range.

[0108]

[0109] A method for manufacturing a fireproof pad according to one embodiment may further include the steps of (C) forming a laminate by sequentially providing an adhesive layer and a fireproof layer on at least one surface of an insulating layer (S30, see FIG. 2) and (D) forming a fireproof pad by hot-roll pressing the laminate (S40, see FIG. 2).

[0110]

[0111] FIG. 7 illustrates one step of the method for manufacturing a fireproof pad of the present invention.

[0112] Referring to FIG. 2 and FIG. 7 together, the method for manufacturing a fireproof pad according to the present invention may further include, after steps (A) and (B), a step (S30) of forming a laminate by sequentially providing an adhesive layer and a fireproof layer on at least one surface of (C) an insulating layer, and a step (D) of forming a fireproof pad by hot roll pressing the laminate (S40).

[0113] (C) Step is to form a laminate by sequentially providing an adhesive layer and a refractory layer on at least one surface of the insulating layer. FIG. 7 illustrates, as an example, that an adhesive layer (20) and a refractory layer (30) are laminated on each of the two surfaces of the insulating layer (10).

[0114] The adhesive layer (20) contains an adhesive material and is provided for the purpose of bonding a refractory layer (30) to an insulating layer (10) that has completed heat curing.

[0115] In one embodiment, the adhesive material may comprise at least one of a silicone-based adhesive material, an acrylic-based adhesive material, and an epoxy-based adhesive material.

[0116] Specifically, the silicone-based adhesive material may comprise a PDMS resin, a crosslinking agent, a catalyst, and a solvent, and may further comprise additives. As the catalyst, a Pt catalyst or a peroxide-based catalyst may be used. As the solvent, toluene or xylene, or a low molecular weight PDMS resin may be used. As the additive, MQ resin or organic / inorganic fillers may be used. For example, the fillers used as additives may include metal inorganic fillers comprising metal particles such as copper, aluminum, or silver; ceramic inorganic fillers comprising silicon dioxide (SiO2), aluminum oxide (Al2O3), aluminum nitride (AlN), boron nitride (BN), or silicon carbide (SiC); or carbon-based fillers comprising graphene powder, graphene sheets, carbon nanotubes, carbon fibers, or diamond fillers, but the examples are not limited thereto.

[0117] For example, an adhesive material of one embodiment comprises a PDMS resin, a crosslinking agent, a catalyst, and a solvent, specifically, 50 to 99 weight% of PDMS-vinyl (poly(dimethyl siloxane)-vinyl terminated) as the PDMS resin, and polymethylhydrogensiloxane (Me3SiO(MeHSiO)) as the crosslinking agent. x It may contain 0.1 to 10 wt% of SiMe3), 0.01 to 3 wt% of Pt catalyst, and 0 to 50 wt% of solvent.

[0118] Or, for example, the adhesive material of one embodiment comprises a PDMS resin, a crosslinking agent, a catalyst, an MQ resin additive, and a solvent, specifically, 10 to 90 weight% of PDMS-vinyl (poly(dimethyl siloxane)-vinyl terminated) as the PDMS resin, and Polymethylhydrogensiloxane (Me3SiO(MeHSiO)) as the crosslinking agent X0.1 to 10 wt% of SiMe3), 0.01 to 3 wt% of Pt catalyst, and as MQ resin TMS (Trimethylsiloxysilicate, (C3H9O 1 / 2 Si) x (O2Si) y It may contain 10 to 90 weight% of resin and 0 to 45 weight% of solvent.

[0119] Or, for example, the adhesive material of one embodiment comprises a PDMS resin, a crosslinking agent, a catalyst, an organic / inorganic filler additive, and a solvent, specifically, 5 to 95 weight% of PDMS-vinyl (poly(dimethyl siloxane)-vinyl terminated) as the PDMS resin, and Polymethylhydrogensiloxane (Me3SiO(MeHSiO)) as the crosslinking agent X It may comprise 0.1 to 10 wt% of SiMe3), 0.01 to 3 wt% of Pt catalyst, 5 to 95 wt% of organic / inorganic filler, and 0 to 45 wt% of solvent.

[0120] As described above, when the adhesive layer (20) includes a silicone-based adhesive material, the adhesive function can be performed through heat curing.

[0121] Alternatively, the acrylic adhesive material may include a cyanoacrylate-based material including cyanoacrylate, methyl cyanoacrylate, ethyl cyanoacrylate, butyl cyanoacrylate, octyl cyanoacrylate, or allyl cyanoacrylate, but the examples are not limited thereto.

[0122] Alternatively, the epoxy adhesive material may include materials having an epoxy structure such as bisphenol A, bisphenol F, novolacs, glycidyl ether, aliphatic, or cycloaliphatic resin, but the examples are not limited thereto.

[0123] In step (C), the adhesive layer (20) is formed by providing the aforementioned adhesive material in a liquid state. In step (D), which will be described later, the adhesive layer (20) is formed as the adhesive material is heat-cured. Therefore, providing the adhesive layer (20) in step (C) means providing the liquid adhesive material to at least one surface of the insulation layer (10) using a slot-die or spray coating method (SD).

[0124] The refractory layer (30) comprises a refractory material. In one embodiment, the refractory material may comprise at least one of mica fibers, glass fibers, basalt fibers, ceramic paper, and aramid fibers. For example, the refractory layer (30) may be provided with the refractory material in the form of a sheet.

[0125] As described above, in step (C), a laminate is formed in which an adhesive layer (20) and a refractory layer (30) are provided in sequence on at least one surface of the insulation layer (10).

[0126] Step (D) is a step of forming a refractory pad by hot-roll pressing the laminate manufactured in Step (C). As shown in FIG. 7, the laminate of the insulating layer (10), the adhesive layer (20), and the refractory layer (30) can be manufactured into a refractory pad (1) by laminating them while being heat-pressed by a hot-roll press (RP-1). Since Step (D) is also performed by a hot-roll press (RP-1), the refractory pad (1) can be manufactured continuously and mass production is possible. Meanwhile, after the hot-roll press (RP-1), heat curing (RC) may be additionally performed as needed, taking into account the curing mechanism of the adhesive layer (20).

[0127]

[0128] As described above, the method for manufacturing a fire-resistant pad according to the present invention comprises: (A) a step of forming a silicone-aerogel composite (S10); (B) a step of forming an insulating layer by hot roll pressing the silicone-aerogel composite (S20); (C) a step of forming a laminate by sequentially providing an adhesive layer and a fire-resistant layer on at least one surface of the insulating layer (S30); and (D) a step of forming a fire-resistant pad by hot roll pressing the laminate (S40), thereby providing a method for manufacturing a fire-resistant pad (1) including an insulating layer (10), an adhesive layer (20), and a fire-resistant layer (30) that can be continuously mass-produced. At this time, based on the total weight of the silicone-aerogel composite, the content of the aerogel is 0.5 weight% or more and 40 weight% or less.

[0129]

[0130] In addition, the fire-resistant pad of the present invention,

[0131] The insulation layer comprises a silicone-aerogel composite including silicone and aerogel, wherein the average thickness of the insulation layer is 0.5 mm or more and 10 mm or less, the thickness deviation is 20% or less, and based on the total weight of the silicone-aerogel composite, the content of the aerogel is 0.5 weight% or more and 40 weight% or less.

[0132]

[0133] FIG. 8 illustrates one embodiment of the fire-resistant pad of the present invention.

[0134] Referring to FIG. 8, a fire-resistant pad according to one embodiment of the present invention may include an insulating layer (10) alone.

[0135] The insulating layer (10) of the present invention comprises silicone (SL) and aerogel (AG), and specifically, may have a structure in which aerogel (AG) is dispersed in cured silicone (SL). In addition, the insulating layer (10) of the present invention may have an average thickness (HH) of 0.5 mm or more and 10 mm or less, and preferably, the average thickness (HH) may be 0.5 mm or more and 3 mm or less. In addition, the thickness variation may be 20% or less, but in the case of the insulating layer (10) shown in FIG. 8, an example is shown in which the thickness variation is 0%.

[0136] Meanwhile, referring to FIG. 3 and FIG. 8 together, the insulation layer (10) may be an insulation layer (10) manufactured by the aforementioned method of manufacturing a fireproof pad. That is, the insulation layer (10) of the present invention is a silicone-aerogel composite (CM) that has been sheeted by a hot roll press (RP), and the descriptions for the silicone (SL) and aerogel (AG) respectively are applied in the same way as those described above for the silicone-aerogel composite (CM). The insulation layer (10) includes silicone (SL) and aerogel (AG), has excellent thermal insulation performance and elasticity, and can be applied as a fireproof pad between cells for the purpose of blocking thermal runaway.

[0137] In addition, the insulation layer (10) can be mass-produced while maintaining a uniform thickness (HH) as it is manufactured using a hot roll press (RP) method. However, the insulation layer (10) of the present invention is not limited to this.

[0138]

[0139] FIG. 9 illustrates one embodiment of the fire-resistant pad of the present invention.

[0140] Referring to FIG. 9, a fire-resistant pad of one embodiment may comprise a patterned insulating layer (10') alone. As an example, an insulating layer (10') with triangular irregularities formed on both sides is shown, but the shape of the pattern is not limited thereto.

[0141] The insulation layer (10') formed with such a pattern may have an average thickness of 0.5 mm or more and 10 mm or less, and preferably, an average thickness of 0.5 mm or more and 3 mm or less. In addition, the thickness variation of the insulation layer (10') may be 20% or less. This means that the difference between the thickness of the thickest part (HH2) and the thickness of the thinnest part (HH1) of the insulation layer (10') is 20% or less of the average thickness.

[0142] Meanwhile, referring to FIG. 5 and FIG. 9 together, the insulation layer (10') may be an insulation layer (10') manufactured by the method of manufacturing the fireproof pad described above. In the manufacturing process of the insulation layer (10'), a hot roll press (RP') with a pattern formed thereon may be used, so that the insulation layer (10') may be mass-produced with a thickness of a certain range while forming a pattern on at least one surface.

[0143]

[0144] FIG. 10 illustrates one embodiment of the fire-resistant pad of the present invention.

[0145] Referring to FIG. 10, the fireproof pad (1) of the present invention may include an insulating layer (10), an adhesive layer (20), and a fireproof layer (30).

[0146] A fire-resistant layer (30) may be provided on at least one surface of the insulation layer (10) and comprises a fire-resistant material. The fire-resistant layer (30) may be provided to improve the fire-resistant performance of the fire-resistant pad (1) and to increase durability and flexibility.

[0147] The adhesive layer (20) is disposed between the insulation layer (10) and the fire-resistant layer (30) and includes an adhesive material. The adhesive layer (20) may be provided for bonding the insulation layer (10) and the fire-resistant layer (30).

[0148] Meanwhile, referring to FIG. 7 and FIG. 10 together, the fireproof pad (1) of one embodiment may be a fireproof pad (1) manufactured by the method of manufacturing the fireproof pad described above. The specific description of the adhesive layer (20) and the fireproof layer (30) may be applied in the same way as described above in FIG. 7. The fireproof pad (1) of the present invention may be mass-produced with a certain thickness range by laminating the adhesive layer (20) and the fireproof layer (30) onto the insulation layer (10) that has been manufactured and then performing a hot roll press (RP-1).

[0149]

[0150] A method for manufacturing a fireproof pad according to one embodiment can mass-produce an insulating layer of uniform thickness in a continuous process by hot-roll-pressing a solid silicone-aerogel composite containing aerogel in a predetermined content range as described above.

[0151] In addition, the method for manufacturing a fire-resistant pad of one embodiment can mass-produce a fire-resistant pad with further improved fire resistance, durability, and flexibility in a uniform thickness range by manufacturing the fire-resistant pad by laminating an adhesive layer and a fire-resistant layer in addition to the insulation layer and then hot-roll pressing.

[0152] In addition, the fireproof pad of one embodiment may have a uniform thickness range.

[0153] Hereinafter, embodiments of the invention are described in detail so that those skilled in the art can easily practice the invention. However, the present invention may be embodied in various different forms and is not limited to the embodiments described herein.

[0154]

[0155] Example 1.

[0156] A solid silicone-aerogel composite was formed by mixing solvent-free silicone and aerogel in a weight ratio of 75:25. The silicone was PDMS resin, specifically Dowsil from Dow Inc. TM7626 was used, and Dow's Syl-off was used as a crosslinking agent. TM 7028 was used, and Dow's Syl-off was used as the Pt catalyst. TM 4000 was used. Cabot EV5200 was used for the aerogel.

[0157] An insulating layer was manufactured by forming the prepared silicone-aerogel composite into a sheet-shaped pad by performing a hot roll pressing process at a temperature of 150°C and a speed of 1 m / min using a roll press with a roll gap set to 0.7 mm. A photograph of the manufactured insulating layer is shown in Fig. 11.

[0158]

[0159] Comparative Example 1.

[0160] Except for mixing silicone and aerogel in a weight ratio of 50:50, a hot roll press process was performed in the same manner as the insulation layer of Example 1, but the silicone-aerogel composite was not sheeted.

[0161]

[0162] Comparative Example 2.

[0163] The insulation layer of Comparative Example 2 was prepared in the same manner as the insulation layer of Example 1, except that silicone and aerogel were mixed in a weight ratio of 30:70. However, the silicone-aerogel composite was not sheeted.

[0164]

[0165] Comparative Example 3.

[0166] A pure aerogel in powder form consisting only of aerogel without silicone was prepared, and a hot roll press process was performed in the same manner as the insulation layer of Example 1, but sheet formation was not achieved.

[0167]

[0168] It can be confirmed that the insulating layer of Example 1 was sheeted by a hot roll press process, and accordingly, a single layer having a continuous and uniform thickness was formed. In addition, it is expected to exhibit sufficient thermal insulation performance by including aerogel.

[0169] It can be confirmed that in the insulation layers of Comparative Examples 1 and 2, the aerogel content exceeds 40 weight% and the silicon content is relatively reduced, resulting in a decrease in inter-particle bonding strength, and consequently, sheet formation through a hot roll press process is not achieved.

[0170] In addition, it was confirmed that Comparative Example 3 could not be applied as a fireproof pad because it did not form into a sheet as it contained only aerogel.

[0171]

[0172] Although 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 by those skilled in the art using the basic concept of the present invention as defined in the following claims are also included within the scope of the present invention.

[0173] [Explanation of the symbol]

[0174] CM: Silicone-aerogel composite

[0175] SL: Silicon

[0176] AG: Aerogel

[0177] 1: Fireproof pad

[0178] 10: Insulation layer

[0179] 20: Adhesive layer

[0180] 30: Refractory layer

[0181] RP: Hot Roll Press

Claims

1. (A) A step of forming a solid silicone-aerogel composite by mixing solvent-free liquid silicone and aerogel; and (B) A step of continuously sheeting the above silicone-aerogel composite using a hot roll press to form an insulating layer; comprising, A method for manufacturing a fireproof pad in which, based on the total weight of the silicone-aerogel composite, the content of the aerogel is 0.5% by weight or more and 40% by weight or less.

2. In Paragraph 1, In step (B) above, the hot roll press includes two facing rolls, and The gap between the two rolls is 0.5mm or more and 10mm or less, and A method for manufacturing a refractory pad in which the pressure of the above hot roll press is 10 kPa or more and 1000 kPa or less.

3. In Paragraph 1, A method for manufacturing a refractory pad in which, in step (B) above, the heating temperature of the hot roll press is 50°C or higher and 150°C or lower.

4. In Paragraph 1, A method for manufacturing a refractory pad in which, in step (B) above, the speed of the hot roll press is greater than 0 mm / s and less than or equal to 100 mm / s.

5. In Paragraph 1, A method for manufacturing a fireproof pad in which the average thickness of the insulation layer is 0.5 mm or more and 10 mm or less, and the thickness deviation is 20% or less.

6. In Paragraph 1, The above hot roll press includes two facing rolls, and A pattern is formed on the surface of the two rolls mentioned above, and A method for manufacturing a fireproof pad in which, in step (B) above, the pattern is formed on the surface of the insulation layer.

7. In Paragraph 1, The above (B) step is, A method for manufacturing a fireproof pad comprising the steps of: providing a pattern film between the hot roll press and the silicone-aerogel composite; and continuously sheeting the silicone-aerogel composite using a hot roll press to form an insulating layer on the surface having a pattern of the pattern film formed thereon.

8. In Paragraph 1, A method for manufacturing a fireproof pad, comprising, after step (B) above, further a step of additionally heat-curing the insulation layer.

9. In Paragraph 1, A method for manufacturing a fireproof pad in which, based on the total weight of the silicone-aerogel composite, the silicone content is 60% by weight or more and 99.5% by weight or less.

10. In Paragraph 1, (C) A step of forming a laminate by sequentially providing an adhesive layer containing an adhesive material and a refractory layer containing a refractory material on at least one surface of the insulation layer; and (D) A step of laminating the above laminates using a hot roll press to form a fireproof pad; further comprising a method for manufacturing a fireproof pad.

11. In Paragraph 10, A method for manufacturing a refractory pad in which, in step (D) above, forming the refractory pad involves further heat-curing the laminate after hot-roll pressing.

12. In Paragraph 10, A method for manufacturing a fireproof pad in which the adhesive material comprises at least one of a silicone-based adhesive material, an acrylic-based adhesive material, and an epoxy-based adhesive material.

13. In Paragraph 10, A method for manufacturing a refractory pad, wherein the refractory material comprises at least one of mica fiber, glass fiber, basalt fiber, ceramic paper, and aramid fiber.

14. In Paragraph 10, A method for manufacturing a fireproof pad in which the adhesive layer is cured by providing the adhesive material through a slot die or spray process.

15. In Paragraph 1, The above aerogel contains SiO2, and The particle size of the above aerogel is 0.01 mm to 1.5 mm, and A method for manufacturing a refractory pad in which the average diameter of the pores of the aerogel is 1 nm to 200 nm.

16. In Paragraph 1, A method for manufacturing a refractory pad in which the above silicone comprises a polydimethylsiloxane-based resin and optionally further comprises at least one of a crosslinking agent and a catalyst.

17. In Paragraph 16, A method for manufacturing a refractory pad, wherein, based on the total weight of the silicone-aerogel composite, the content of the polydimethylsiloxane-based resin is 47% by weight or more and 99.5% by weight or less, the content of the crosslinking agent is 0% by weight or more and 10% by weight or less, and the content of the catalyst is 0% by weight or more and 3% by weight or less.

18. A thermal insulation layer comprising a silicone-aerogel composite including silicone and aerogel, and The average thickness of the above insulation layer is 0.5mm or more and 10mm or less, and the thickness deviation is 20% or less, and A fireproof pad having an aerogel content of 0.5% by weight or more and 40% by weight or less, based on the total weight of the silicone-aerogel composite.

19. In Paragraph 18, A refractory layer provided on at least one surface of the above-mentioned insulation layer; and A fire-resistant pad further comprising an adhesive layer disposed between the insulation layer and the fire-resistant layer.

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