Battery insulation sheet, manufacturing method thereof, and battery module comprising the battery insulation sheet

Patent metadata

Field	Value
Publication number	US-2025062516-A1
Application number	US-202418675765-A
Country	US
Kind code	A1
Filing date	May 28, 2024
Priority date	Aug 16, 2023
Publication date	Feb 20, 2025
Grant date	—

Abstract

Example embodiments include a battery insulation sheet having a structure in which a first substrate, an aerogel layer, and a second substrate are laminated, wherein opposite surfaces of the aerogel layer is in contact with the first substrate or the second substrate adjacent thereto. Example embodiments also include a method of manufacturing a battery insulation sheet, and a battery module including the battery insulation sheet.

First claim

What is claimed is:

1 . A battery insulation sheet comprising:
a first substrate; an aerogel layer; and a second substrate; wherein: the first substrate, the aerogel layer and the second substrate are sequentially laminated; and each of opposite surfaces of the aerogel layer is in contact with the first substrate or the second substrate adjacent thereto.

2 . The battery insulation sheet as claimed in claim 1 , wherein a separate layer comprising an adhesive between the aerogel layer and the first substrate or the second substrate is omitted.

3 . The battery insulation sheet as claimed in claim 1 , wherein the aerogel layer satisfies:

0.1
≤

PD
⁢
1

≤
0.5

,

PD
⁢
1

=

PA
/
PB

;

where PA indicates a mass per unit volume (g/cm 3 ) of the aerogel layer after a pressure of 0 kN is vertically applied to the aerogel layer, and PB indicates the mass per unit volume (g/cm 3 ) of the aerogel layer after a pressure of 5 kN is vertically applied to the aerogel layer.

4 . The battery insulation sheet as claimed in claim 1 , wherein the aerogel layer satisfies:

0.1
≤

PD
⁢
2

≤
0.4

,

PD
⁢
2

=

PB
/
PC

;

where PB indicates a mass per unit volume (g/cm 3 ) of the aerogel layer after a pressure of 5 kN is vertically applied to the aerogel layer, and PC indicates the mass per unit volume (g/cm 3 ) of the aerogel layer after a pressure of 20 kN is vertically applied to the aerogel layer.

5 . The battery insulation sheet as claimed in claim 1 , wherein at least one of the first substrate and the second substrate comprises at least one of a resin, a metal, and an inorganic material other than the metal.

6 . The battery insulation sheet as claimed in claim 1 , wherein at least one of the first substrate and second substrate comprises an inorganic material having an air permeability of about 800 sec/100 cc to 40,000 sec/100 cc.

7 . The battery insulation sheet as claimed in claim 1 , wherein the aerogel layer comprises at least one of a fibrous support, an aerogel, and a functional material comprising a binder, a dispersant, or a combination thereof.

8 . The battery insulation sheet as claimed in claim 7 , wherein the fibrous support comprises at least one of natural fiber, silica fiber, glass fiber, ceramic fiber, carbon fiber, graphite fiber, mineral fiber, and polymer fiber.

9 . The battery insulation sheet as claimed in claim 7 , wherein the aerogel has a BET specific surface area of about 500 m 2 /g to 1,000 m 2 /g.

10 . The battery insulation sheet as claimed in claim 7 , wherein the binder comprises an aqueous polymer binder.

11 . The battery insulation sheet as claimed in claim 7 , wherein the dispersant is at least one of a surfactant and a phosphate-based salt.

12 . The battery insulation sheet as claimed in claim 7 , wherein at least one of: the fibrous support is included so as to account for about 25 wt % to 60 wt %, the aerogel is included so as to account for 3 about 0 wt % to 70 wt %, and the binder is included so as to account for about 2 wt % to 15 wt %, based on a total amount of the aerogel layer.

13 . The battery insulation sheet as claimed in claim 7 , wherein at least one of: the fibrous support is included so as to account for about 25 wt % to 60 wt %, the aerogel is included so as to account for about 30 wt % to 70 wt %, the binder is included so as to account for about 2 wt % to 15 wt %, and the dispersant is included so as to account for about 0.1 wt % to 5 wt %, based on a total amount of the aerogel layer.

14 . The battery insulation sheet as claimed in claim 1 , wherein:
at least one of the first substrate and the second substrate has a thickness of about 0.01 mm to 5 mm; and the aerogel layer has a thickness of about 1 mm to 10 mm.

15 . A method of manufacturing a battery insulation sheet, the method comprising:
applying an aerogel composition to a first substrate; laminating a second substrate on the applied aerogel composition to manufacture a laminate; controlling a thickness of the laminate; and drying the laminate.

16 . The method as claimed in claim 15 , wherein the aerogel composition is manufactured by:
mixing a solvent with a functional material comprising a binder, a dispersant, or a combination thereof to manufacture a solvent mixture; mixing the solvent mixture with aerogel powder to manufacture an aerogel mixture; and mixing the aerogel mixture with a fibrous support to manufacture the aerogel composition.

17 . The method as claimed in claim 16 , wherein the solvent comprises at least one of a polar solvent and a non-polar solvent.

18 . The method as claimed in claim 15 , wherein controlling the thickness of the laminate comprises controlling the thickness of the laminate by pressing using a roller.

19 . The method as claimed in claim 15 , wherein drying the laminate is performed at a temperature of about 25° C. to 100° C.

20 . A battery module comprising:
a plurality of cells; and the battery insulation sheet as claimed in claim 1 between the plurality of cells, wherein the first substrate and the second substrate of the battery insulation sheet are disposed so as to face cells adjacent thereto.

Assignees

• Samsung Sdi Co Ltd
• Daehyup Tech Co Ltd

Inventors

• Woo Myung Heui
• Ra Ha Na
• Park Hye Jin
• Yang Seung Yong
• Lee Jae Hyun
• Ryu Bo Kyung
• Kim Sang Hoon
• Hwang Jong Pil
• Choi Hyung Sek
• Kim Ho Joon

Classifications

• B32B2457/10

  Batteries · CPC title

• B32B2307/206

  Insulating · CPC title

• B32B2037/243

  Coating · CPC title

• B32B2262/101

  Glass fibres · CPC title

• B32B2266/126

  Aerogel, i.e. a supercritically dried gel · CPC title