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KR-20260062984-A - Polyurethane-based elastomer foam containing an adhesion promoter suitable for battery potting

KR20260062984AKR 20260062984 AKR20260062984 AKR 20260062984AKR-20260062984-A

Abstract

The present invention provides a reaction system for manufacturing a polyurethane-based elastomer foam, comprising: a reaction system comprising: a component A) an isocyanate component comprising a hard block prepolymer as an isocyanate component; and a component B) an isocyanate-reactive component comprising a polyol, a first chain extender and a second chain extender different from the first chain extender, wherein the first chain extender and the second chain extender are each an aliphatic diol having 2 to 6 carbon atoms, one or more adhesion promoters, blowing agents, optionally a surfactant, and optionally a catalyst.

Inventors

  • 베르베케 한스
  • 반 에쉐 루크
  • 베르텔스 필립
  • 반그라임데 바르트
  • 크레이머 마이클

Assignees

  • 헌트스만 인터내셔날, 엘엘씨

Dates

Publication Date
20260507
Application Date
20240830
Priority Date
20230911

Claims (20)

  1. As a reaction system for manufacturing a polyurethane-based elastomer foam, the reaction system Component A) an isocyanate component comprising a hard block prepolymer as an isocyanate component; and Component B) as an isocyanate-reactive component, Polyol; A chain extender comprising a first chain extender and a second chain extender different from the first chain extender, wherein the first chain extender and the second chain extender are aliphatic diols each having 2 to 6 carbon atoms; One or more adhesion promoters; Injection agent; Optionally a surfactant; and Optional catalyst isocyanate-reactive components including A reaction system including
  2. A reaction system according to claim 1, wherein the hard block prepolymer is formed from a reaction between an isocyanate composition and one or more isocyanate-reactive compounds, each having a molar mass of less than 500 g/mol.
  3. A reaction system according to claim 1 or 2, wherein the hard block prepolymer is an MDI-based prepolymer.
  4. A reaction system according to claim 1 or 2, wherein the NCO% of the hard block prepolymer is in the range of about 15% to about 30%.
  5. A reaction system according to any one of claims 1 to 4, wherein the average functionality of the hard block prepolymer is in the range of about 1.7 to about 2.3.
  6. A reaction system according to any one of claims 1 to 5, wherein the isocyanate component further comprises a polyisocyanate compound different from the hard block prepolymer.
  7. In claim 6, a reaction system in which the polyisocyanate compound is a polymeric MDI.
  8. A reaction system according to claim 6 or 7, wherein the NCO% of the polyisocyanate compound is in the range of about 25% to about 40%.
  9. A reaction system according to any one of claims 6 to 8, wherein the average functional value of the polyisocyanate compound is in the range of about 2.4 to about 3.0.
  10. A reaction system according to any one of claims 6 to 9, wherein the weight ratio of the hard block prepolymer to the polyisocyanate compound in the isocyanate component is in the range of 70:30 to 90:10.
  11. A reaction system according to any one of claims 1 to 10, wherein the polyol is a polyether polyol.
  12. A reaction system according to any one of claims 1 to 11, wherein the polyol has a hydroxyl value in the range of about 10 mg KOH/g to about 180 mg KOH/g.
  13. A reaction system according to any one of claims 1 to 12, wherein the polyol has a weight-average molecular weight in the range of about 1000 g/mol to about 7500 g/mol.
  14. A reaction system according to any one of claims 1 to 13, wherein the polyol has an average functional value in the range of about 2.0 to about 3.0.
  15. A reaction system according to any one of claims 1 to 14, wherein the first chain extender and the second chain extender are each a linear aliphatic diol, preferably any one independently selected from monoethylene glycol (MEG), diethylene glycol (DEG), 1,3-propanediol, 1,2-propanediol, 2-methyl-1,3-propanediol, 3-chloro-1,2-propanediol, 1,4-butanediol, 1,3-butanediol, 2,3-butanediol, 2-ethyl-1,4-butanediol, 1,5-pentanediol, 1,3-pentanediol, 3-methyl-1,5-pentanediol, 2-methyl-2,4-pentanediol, 1,6-hexanediol, 1,2-hexanediol, and dipropylene glycol.
  16. A reaction system according to any one of claims 1 to 15, wherein the first chain extender is monoethylene glycol (MEG) and/or the second chain extender is diethylene glycol (DEG).
  17. A reaction system according to any one of claims 1 to 16, wherein one or more adhesion promoters are independently selected from phosphoric acid or its derivatives, acid-functional polyesters, polyester alkyl ammonium salts, acid-functional acrylics, epoxy resins, siloxanes, and silanes.
  18. A reaction system according to any one of claims 1 to 17, wherein one or more adhesion promoters are independently selected from acid-functional polyesters and polyester alkyl ammonium salts.
  19. A reaction system according to any one of claims 1 to 18, wherein one of the one or more adhesion promoters is a polyester alkyl ammonium salt having an acid value of about 10 to about 50 mg KOH/g and an amine value of about 10 to about 50 mg KOH/g.
  20. A reaction system according to any one of claims 1 to 19, wherein the one or more adhesion promoters include a first adhesion promoter and a second adhesion promoter different from the first adhesion promoter.

Description

Polyurethane-based elastomer foam containing an adhesion promoter suitable for battery potting Cross-reference regarding related patents This application claims priority to U.S. Patent 63/537,623, filed September 11, 2023. The said application is incorporated herein by reference. Technology field The present invention relates to a reaction system for manufacturing a polyurethane-based elastomer foam. The present invention also relates to a method for manufacturing a polyurethane-based elastomer foam, a polyurethane-based elastomer foam, a method for potting a battery pack, a potted battery pack, and a reaction system in battery potting or a use of the polyurethane-based elastomer foam. Polyurethane-based elastomer foam is particularly suitable for use as a potting material for battery packs designed for automobiles, such as electric vehicles. Polyurethane-based elastomer foams are used for various purposes. One of them is as a battery potting material (or battery encapsulation material). Battery potting is a process of partially or completely filling a battery pack or mold containing battery cells with a material to at least partially encapsulate or surround the battery cells with said material. Generally, the purpose of battery potting is to protect the battery cells by, for example, providing resistance to mechanical shock and vibration, creating a seal against moisture, solvents, and corrosive agents, and assisting in electrical insulation and heat dissipation. Battery potting is particularly important for battery packs used in electric vehicles (EVs), which contain numerous battery cells requiring protection from harsh conditions such as large temperature fluctuations, mechanical shock, vibration, and moisture. Therefore, battery potting materials must be lightweight and easy to process, while possessing excellent mechanical properties over a wide temperature range—specifically tensile properties (e.g., tensile strength, modulus (also known as Young's modulus), and elongation at break)—to operate effectively in EVs. Furthermore, battery potting materials must adhere sufficiently to battery cells even under wet conditions. If the adhesion of the battery potting material is poor, its performance naturally degrades. However, current battery potting materials may be too brittle to provide stable properties over the required temperature range, or they may fail to provide the desired level of elongation over the required temperature range. The inability of current battery potting materials to exhibit desired tensile properties over the required temperature range limits their effectiveness as battery potting materials, particularly in EVs. For example, polysiloxane (silicon) materials can be used as battery potting materials. However, the modulus of silicon polymers is often lower than the modulus required to be effective when used in EVs. Furthermore, silicon is expensive, and its processability is generally more difficult than that of other materials, such as polyurethane-based elastomers. As the demand for EVs increases, the demand for effective new battery potting materials is also rising. Consequently, there is increasing demand for polyurethane-based elastomer foams that offer improved tensile properties (e.g., tensile strength, modulus, and elongation at break) and provide an ideal balance of tensile and chemical properties for use as battery potting materials in EVs. Additionally, there is a demand for battery potting materials that adhere effectively to the surface of battery cells. Therefore, there is a demand for a polyurethane-based elastomer foam that can be used as a battery potting material and possesses an ideal balance of tensile properties (e.g., tensile strength, modulus, and elongation at break) and chemical properties for battery potting materials, particularly for EV batteries. Additionally, there is a demand for a battery potting material that effectively adheres to the surface of a battery cell. The present invention addresses the aforementioned problems and requirements. In a first aspect, a reaction system for manufacturing a polyurethane-based elastomer foam is provided, comprising: an isocyanate component A) comprising a hard block prepolymer as an isocyanate component; and a reaction system comprising an isocyanate-reactive component B) comprising a polyol as an isocyanate-reactive component; a chain extender comprising a first chain extender and a second chain extender different from the first chain extender, wherein the first chain extender and the second chain extender are each an aliphatic diol having 2 to 6 carbon atoms; one or more adhesion promoters; a blowing agent; optionally a surfactant; and optionally a catalyst. Surprisingly, the inventors have discovered that a polyurethane-based elastomer foam having an ideal balance of properties for use as a battery potting material can be produced using the aforementioned reaction system. Specifically, the polyurethane-based elast