Electric cell potting compound and method of making
A battery module comprising an electric cell and a potting compound associated with the electric cell. The potting compound is formed of a flame retardant component; a first component having an isocyanate reactive compound and water; and a second component having an isocyanate compound. The potting compound is a foam.
1. A potting composition comprising:
a first component comprising an isocyanate reactive compound and a blowing agent;
a second component comprising an isocyanate compound; and
a flame retardant component in an amount of at least 20% by weight based on the total weight of the potting composition,
wherein the flame retardant component is liquid at a temperature from 25° C. to 35° C.
2. The potting composition of claim 1 , wherein the flame retardant component exhibits a viscosity from about 30 cP to about 2000 cP at a temperature from 25° C. to 35° C.
3. The potting composition of claim 1 , wherein the potting composition is configured to cure to form a foam potting compound exhibiting at least a V2 level flame resistance as measured by the UL 94 Test for Flammability of Plastics.
4. The potting composition of claim 1 , wherein the potting composition is configured to cure to form a foam potting compound having a density of less than 0.60 g/cm 3 .
5. The potting composition of claim 1 comprising at least 25% by weight the flame retardant component based on the total weight of the potting composition.
6. The potting composition of claim 1 comprising at least 30% by weight the flame retardant component based on the total weight of the potting composition.
7. The potting composition of claim 1 , wherein the flame retardant component has a viscosity of no greater than 300 cP at a temperature from 25° C. to 35° C.
8. The potting composition of claim 1 , wherein the first component has a viscosity from greater than one to less than 1500 cP, and wherein the second component has a viscosity from greater than one to less than 1000 cP, all at a temperature from 25° C. to 35° C.
9. The potting composition of claim 1 , wherein the flame retardant component is present in one or both of the first component and the second component.
10. The potting composition of claim 1 , wherein the first component, second component, and flame retardant component are configured such that a mixture of the first component, second component, and flame retardant component exhibits a viscosity no greater than 2000 cP within one minute after forming, when measured at an ambient temperature of about 25° C., with a Brookfield viscometer at a spindle speed of 20 rpm.
11. A potting composition comprising:
a first component comprising an isocyanate reactive compound and a blowing agent;
a second component comprising an isocyanate compound; and
at least 20% by weight, based on the total weight of the potting composition, a flame retardant component that is liquid at a temperature from 25° C. to 35° C.,
wherein at least one of the following (a) and (b) are exhibited when measured with a Brookfield viscometer at a spindle speed of 20 rpm at a temperature from 25° C. to 35° C.:
(a) the first component has a viscosity from greater than one to less than 1500 cP,
(b) the second component has a viscosity from greater than one to less than 1000 cP.
12. The potting composition of claim 11 comprising at least 25% by weight the flame retardant component based on the total weight of the potting composition.
13. The potting composition of claim 11 , wherein the flame retardant component has a viscosity of no greater than 300 cP at a temperature from 25° C. to 35° C.
14. The potting composition of claim 11 , wherein the first component, second component, and flame retardant are configured to be combined to form a mixture having a viscosity no greater than 2000 cP within one minute after forming, when measured at an ambient temperature of about 25° C., with a Brookfield viscometer at 20 rpm.
15. A potting composition comprising:
a first component comprising from 20 wt. % to 50 wt. % polyether polyol, and from 0.4 wt. % to 2.0 wt. % blowing agent, all based on the total weight of the first component;
a second component comprising from 10 wt. % to 90 wt. % an isocyanate compound including MDI, based on the total weight of the second component; and
a liquid flame retardant component in an amount of least 20% by weight based on the total weight of the potting composition,
wherein a mixture of the first component, second component, and flame retardant component exhibit a viscosity no greater than 2000 cP within one minute after forming, when measured at an ambient temperature of about 25° C. with a Brookfield viscometer at 20 rpm.
16. The potting composition of claim 15 comprising at least 25% by weight the flame retardant component based on the total weight of the potting composition.
17. The potting composition of claim 15 , wherein the potting composition is configured to cure to form a foam potting compound exhibiting at least a V2 level flame resistance as measured by the UL 94 Test for Flammability of Plastics.
18. The potting composition of claim 15 , wherein the flame retardant component has a viscosity of no greater than 300 cP at a temperature from 25° C. to 35° C.
19. The potting composition of claim 15 , wherein the potting composition is configured to cure to form a foam potting compound having a density of less than 0.60 g/cm 3 .
20. The potting composition of claim 15 comprising at least 30% by weight the flame retardant component based on the total weight of the potting composition.
21. The potting composition of claim 1 , wherein the flame retardant component comprises a non-halogenated phosphate ester.
22. The potting composition of claim 1 , wherein the flame retardant component comprises a halogenated phosphate ester.
23. The potting composition of claim 1 , wherein the first component comprises an isocyanate reactive compound having a functionality of three or more.
24. The potting composition of claim 1 , wherein the isocyanate reactive compound comprises at least one polyether polyol.
25. The potting composition of claim 1 , wherein the isocyanate compound includes polymeric MDI.
26. The potting composition of claim 1 , wherein
the first component includes
from 20 wt. % to 40 wt. % at least one polyether polyol,
from 20 wt. % to 50 wt. % a phosphate ester flame retardant, and
from 0.4 wt. % to 2.0 wt. % a blowing agent, all based on the total weight of the first component; and
the second component includes
from 10 wt. % to 90 wt. % MDI and
from 10 wt. % to 90 wt. % a phosphate ester flame retardant, all based on the total weight of the second component.
27. The potting composition of claim 1 , wherein the potting composition is configured to cure to form a foam potting compound exhibiting at least a V0 level flame resistance as measured by the UL 94 Test for Flammability of Plastics.
28. The potting composition of claim 11 , wherein the flame retardant component is present in both the first component and the second component.
29. The potting composition of claim 11 comprising greater than 30% by weight the flame retardant component based on the total weight of the potting composition.
30. The potting composition of claim 11 , wherein the potting composition is configured to cure to form a foam potting compound exhibiting at least a V0 level flame resistance as measured by the UL 94 Test for Flammability of Plastics.