Polyurethane Foam Composition for Flame-Retardant Battery Cell Cushioning

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Solution Overview

Problem

Polyurethane foam used in electronic goods and battery cells faces issues with uncontrolled burning due to flammability, limited flame retardancy, and challenges with suction pressure during automated assembly processes, leading to production complexities and increased costs.

Innovation Solution

A polyurethane foam composition comprising a polyol mixture with specific polyol-based compounds, an isocyanate-based curing agent, and a filler, which provides excellent flame retardancy, suction properties, and low density, facilitating high suction pressure and improved dimensional stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If flame retardant composed of halogen compound is added to polyurethane foam, then flame retardancy is improved, but toxic gas is generated during combustion causing human and environment-related problems

Engineering Contradiction:

Improveflame retardancyVSAvoidtoxic gas during combustion

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by replacing halogen compounds with non-halogen flame retardant additives, thereby maintaining flame retardancy while eliminating toxic gas generation during combustion

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the harmful effect of flammability into a beneficial controlled flame retardancy property by using alternative flame retardant mechanisms that do not produce toxic gases, turning a dangerous characteristic into a safe one

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Stress or pressure

If density of polyurethane foam is increased to increase suction pressure, then suction pressure is improved, but production cost and process complexity increase

Engineering Contradiction:

Improvesuction pressureVSAvoidprocess complexity

Core Design Contradiction:

Stress or pressureVSDevice complexity

Solution Approach 1:

The patent changes the density parameter to an optimal range that provides sufficient suction pressure for automated assembly while avoiding excessive density that would increase production cost and process complexity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates local quality variations in the foam structure through controlled cell morphology and size distribution, achieving high suction pressure at specific contact points without requiring overall high density throughout the entire foam structure

Inventive Principle:

Principle #3Local quality

3Reliability

If flame retardant is added to polyurethane foam, then flame retardancy is improved, but the method is not fundamental and production process becomes complicated

Engineering Contradiction:

Improveflame retardancyVSAvoidproduction process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the flame retardant properties directly into the polyurethane foam base material through chemical integration of flame retardant additives during the foam formation process, creating a unified single-step production method that eliminates separate lamination steps

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates a universal flame-retardant polyurethane foam composition that simultaneously provides structural foam properties and flame retardancy in a single material system, eliminating the need for separate flame retardant layers or additional processing steps

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The composition results in polyurethane foam with high suction pressure, excellent flame resistance, and dimensional stability, enabling efficient automated processing and effective buffering of battery cell volume changes, while maintaining reduced density and cost-effectiveness.

Implementation Method 1

a polyol mixture containing a first polyol-based compound having a glass transition temperature of −50° C. or lower, a second polyol-based compound having a weight-average molecular weight of 5,000 g/mol to 30,000 g/mol and containing at least three functional groups reactive with an isocyanate group

Methodology Applied

Scientific EffectPolymerization: Chemical Bonding

Implementation Method 2

a third polyol-based compound having a heat release capacity of 500 J/g·K or less

Methodology Applied

Scientific EffectHeat capacity: Calorimetry

Data Source

PatentUS20230323063A1Polyurethane Foam Composition and Polyurethane Foam Comprising Cured Product Thereof

Publication Date: 2023.10.12 LG CHEM LTD

AI summary

The present invention relates to a polyurethane foam composition and polyurethane foam including a cured product thereof. The polyurethane foam composition comprises a poly mixture comprising a first polyol-based compound having a glass transition temperature of −50° C. or lower, a second polyol-based compound having a weight-average molecular weight of 5,000 g/mol to 30,000 g/mol and comprising at least three functional groups reactive with an isocyanate group, and a third polyol-based compound having a heat release capacity of 500 J/g·K or less; an isocyanate-based curing agent; and a filler.