Thermal insulation materials and methods thereof

Patent metadata

Field	Value
Publication number	US-2021197520-A1
Application number	US-201817058258-A
Country	US
Kind code	A1
Filing date	Jul 23, 2018
Priority date	Jul 23, 2018
Publication date	Jul 1, 2021
Grant date	—

Abstract

Provided is a multilayer thermal insulator and related method that use a non-woven core layer comprising non-meltable and flame-resistant polymeric fibers. One or more scrims are disposed on the opposing major surfaces of the non-woven core layer, and a peripheral edge of the one or more scrims is either edge sealed or capable of being edge sealed to substantially encapsulate the non-woven core layer within the one or more scrims. Optionally, a binder is provided on the scrims or non-woven core layer to facilitate edge sealing. The provided insulators are essentially dust-free and capable of passing stringent flammability standards.

First claim

1 - 15 . (canceled)

16 . A multilayer thermal insulator comprising:
a non-woven core layer comprising non-meltable, flame-resistant polymeric fibers; and one or more scrims disposed on opposing major surfaces of the non-woven core layer, wherein a peripheral edge of the one or more scrims is either edge sealed or capable of being edge sealed to substantially encapsulate the non-woven core layer within the one or more scrims.

17 . The multilayer thermal insulator of claim 16 , wherein the non-meltable polymeric fibers comprise carbon fiber, carbon fiber precursor, or combination thereof.

18 . The multilayer thermal insulator of claim 16 , further comprising a binder disposed on the scrims and/or the non-woven core layer, wherein the peripheral edge is either edge sealed or capable of being edge sealed by melting at least part of the binder.

19 . The multilayer thermal insulator of claim 18 , wherein the binder is provided by a coating disposed on the one or more scrims and/or non-woven core layer.

20 . The multilayer thermal insulator of claim 19 , wherein the coating comprises a polymer latex.

21 . The multilayer thermal insulator of claim 19 , wherein the coating further comprises a flame retardant additive.

22 . The multilayer thermal insulator of claim 21 , wherein the flame retardant additive comprises ammonium polyphosphate.

23 . The multilayer thermal insulator of claim 16 , wherein the non-woven core layer further comprises reinforcing fibers each having an outer surface comprised of a polymer with a melting temperature of from 100° C. to 300° C.

24 . The multilayer thermal insulator of claim 16 , wherein each scrim comprises flame-resistant polyester fibers.

25 . The multilayer thermal insulator of claim 16 , wherein the peripheral edge includes both the non-woven core layer and the one or more scrims.

26 . The multilayer thermal insulator of claim 16 , wherein the one or more scrims extend beyond the non-woven core layer such that the peripheral edge includes the scrims but excludes the non-woven core layer.

27 . A battery assembly for an electric vehicle comprising the multilayer thermal insulator of claim 16 .

28 . A method of making a multilayer thermal insulator containing a non-woven core layer comprising non-meltable, flame-resistant polymeric fibers, the method comprising:
providing a scrim along each major surface of the non-woven core layer, and edge sealing a peripheral edge of the scrim(s) to substantially encapsulate the non-woven core layer within the scrim(s).

29 . The method of claim 28 , wherein each scrim comprises flame-resistant polyester fibers.

30 . The method of claim 28 , wherein edge sealing the peripheral edge comprises:
providing a binder on the scrim(s) and/or the non-woven core layer, and applying heat to melt the binder along the peripheral edge.

Assignees

• 3M Innovative Properties Co

Inventors

• Li Mingzhu
• Wu Pingfan
• Wu Tien Tsung
• Pyun Eumi
• Cai zhong hai
• Pan Qisheng

Classifications

• B32B2457/04

  Insulators · CPC title

• B32B2262/0284

  Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT] · CPC title

• B32B2262/0269

  Aromatic polyamide fibres · CPC title

• B32B2250/40

  Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA · CPC title

• B32B2250/24

  All layers being polymeric · CPC title