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 method of potting an electric cell, the method comprising:
positioning a liquid potting composition in a space defined between a side of a first electric cell positioned in a container and at least one of a side of a second electric cell and a side of the container;
allowing the liquid potting composition to flow to a substantially level height in the container; and
allowing the potting composition to harden to form a potting compound,
the liquid potting composition comprising:
an isocyanate reactive compound;
a blowing agent;
an isocyanate compound; and
a liquid flame retardant component in an amount greater than 10% by weight.
2. The method of claim 1 , wherein the liquid potting composition comprises the liquid flame retardant component in an amount greater than 15% by weight.
3. The method of claim 1 , wherein the liquid potting composition comprises the liquid flame retardant component in an amount greater than 20% by weight.
4. The method of claim 1 , wherein the liquid potting composition comprises the liquid flame retardant component in an amount greater than 30% by weight.
5. The method of claim 1 , wherein the potting compound is a polyurethane foam potting compound exhibiting at least a V2 level flame resistance as measured by the UL 94 Test for Flammability of Plastics using a sample having a width of 13 mm and a thickness of 9.5 mm.
6. The method of claim 1 , wherein the potting compound is a polyurethane foam potting compound exhibiting at least a V0 level flame resistance as measured by the UL 94 Test for Flammability of Plastics using a sample having a width of 13 mm and a thickness of 9.5 mm.
7. The method of claim 1 , wherein the potting compound is a polyurethane foam potting compound having a density of less than 0.60 g/cm 3 .
8. The method of claim 1 , wherein the liquid flame retardant component exhibits a viscosity from 30 cP to 2000 cP at a temperature from about 25° C. to about 35° C.
9. The method of claim 1 , wherein the liquid potting composition includes a liquid phosphate ester in an amount greater than 15% by weight.
10. The method of claim 1 , wherein the liquid potting composition includes a liquid halogenated phosphate ester in an amount greater than 15% by weight.
11. The method of claim 1 , wherein the isocyanate reactive compound exhibits a viscosity from greater than one cP to less than 800 cP, the isocyanate compound exhibits a viscosity from greater than one cP to less than 1000 cP, and the liquid flame retardant component exhibits a viscosity from 30 cP to 300 cP, all at a temperature from 25° C. to 35° C.
12. A method of potting an electric cell, the method comprising:
positioning a liquid potting composition in an enclosed space defined by a wall of a case, the case containing at least one electric cell,
the liquid 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 one of the first and second component including a flame retardant component in an amount greater than 10% by weight based on the total weight of the liquid potting composition,
wherein at least one of (a) and (b) are exhibited:
(a) the first component has a viscosity from greater than one cP to less than 1500 cP at 25° C., and
(b) the second component has a viscosity from greater than one cP to less than 1000 cP at 25° C.
13. The method of claim 12 further comprising allowing the liquid potting composition to flow to a substantially level height in the case before forming a potting compound.
14. The method of claim 13 , wherein the potting compound is a polyurethane foam potting compound having a density of less than 0.60 g/cm 3 .
15. The method of claim 12 , wherein the first component has a viscosity from greater than one cP to less than 1500 cP, and wherein the second component has a viscosity from greater than one cP to less than 1000 cP, all at a temperature from 25° C. to 35° C.
16. The method of claim 12 , wherein the liquid potting composition comprises the flame retardant component in an amount greater than 15% by weight.
17. The method of claim 12 , wherein the liquid potting composition comprises the flame retardant component in an amount greater than 20% by weight, and the flame retardant component is a liquid phosphate ester.
18. The method of claim 12 , wherein the liquid potting composition comprises the flame retardant component in an amount greater than 30% by weight.
19. The method of claim 12 , wherein the flame retardant component exhibits a viscosity from 30 cP to 2000 cP at a temperature from about 25° C. to about 35° C.
20. The method of claim 12 , wherein the flame retardant component includes a liquid phosphate ester in an amount greater than 15% by weight.
21. The method of claim 12 , wherein the flame retardant component includes a liquid halogenated phosphate ester in an amount greater than 15% by weight.
22. A method of potting an electric cell, the method comprising:
positioning a liquid potting composition in a space defined between a side of a first electric cell positioned in a container and at least one of a side of a second electric cell and a side of the container,
the liquid potting composition having sufficient flowability such that the liquid potting composition settles at a substantially level height in the space before forming a polyurethane foam potting compound exhibiting at least a V2 level flame resistance as measured by the UL 94 Test for Flammability of Plastics using a sample having a width of 13 mm and a thickness of 9.5 mm.
23. The method of claim 22 , wherein the foam polyurethane potting compound exhibits at least a V0 level flame resistance as measured by the UL 94 Test for Flammability of Plastics.
24. The method of claim 22 , wherein the foam polyurethane potting compound has a density of less than 0.60 g/cm 3 .
25. The method of claim 22 , wherein the liquid potting composition includes a liquid phosphate ester in an amount greater than 15% by weight.
26. The method of claim 12 , wherein the liquid potting composition includes a liquid halogenated phosphate ester in an amount greater than 15% by weight.