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 battery module comprising:
an electric cell potted in a potting compound,
the potting compound comprising
a cured mixture of
a first component including an isocyanate reactive compound and
a second component including an isocyanate compound; and
a liquid flame retardant component in an amount of at least 15% by weight, based on the total weight of the potting compound; and
a plurality of microballoons within the cured mixture;
the potting compound exhibiting a density of no greater 0.60 g/cm 3 .
2. The battery module of claim 1 , wherein the potting compound has at least a V2 level flame resistance as measured by the UL 94 Test for Flammability of Plastics.
3. The battery module of claim 1 , wherein the potting compound has at least a V1 level flame resistance as measured by the UL 94 Test for Flammability of Plastics.
4. The battery module of claim 1 , wherein the potting compound has at least a V0 level flame resistance as measured by the UL 94 Test for Flammability of Plastics.
5. The battery module of claim 1 , wherein the first component has a viscosity from greater than one to less than 100,000 cP, and wherein the second component has a viscosity from greater than one to less than 50,000 cP, all at a temperature from about 25° C. to about 35° C.
6. The battery module 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 about 25° C. to about 35° C.
7. The battery module of claim 1 , wherein the liquid flame retardant component is present in an amount of at least 20 wt. %, based on the total weight of the potting compound.
8. The battery module of claim 1 , wherein the liquid flame retardant component is present in an amount of at least 25 wt. %, based on the total weight of the potting compound.
9. The battery module of claim 1 , wherein the liquid flame retardant component is present in an amount of at least 30 wt. %, based on the total weight of the potting compound.
10. The battery module of claim 1 , wherein the liquid flame retardant includes a phosphate ester.
11. The battery module of claim 1 , wherein the isocyanate reactive compound has an isocyanate reactive functionality of three or more.
12. The battery module of claim 1 , wherein the isocyanate compound has an isocyanate functionality of two or greater.
13. The battery module of claim 1 , wherein the battery module includes a plurality of electric cells, each electric cell having a bottom, a top, and a length defined therebetween, the potting compound being at a substantially level height.
14. A battery module comprising:
a first electric cell potted in a potting compound, the potting compound comprising a cured polyurethane compound having a plurality of microballoons positioned within the cured polyurethane compound,
wherein the potting compound exhibits at least a V2 level flame resistance as measured by the UL 94 Test for Flammability of Plastics, and
wherein the potting compound has a density of no greater than 0.60 g/cm 3 .
15. The battery module of claim 14 , wherein the potting compound has at least a V1 level flame resistance as measured by the UL 94 Test for Flammability of Plastics.
16. The battery module of claim 14 , wherein the potting compound has at least a V0 level flame resistance as measured by the UL 94 Test for Flammability of Plastics.
17. A battery potting composition comprising
a first component including an isocyanate reactive compound;
a second component including an isocyanate compound;
a liquid flame retardant component in an amount of at least 15% by weight, based on the total weight of the battery potting composition; and
a plurality of microballoons;
the battery potting composition configured to cure to form a battery potting compound exhibiting a density of no greater 0.60 g/cm 3 and exhibit at least a V2 level flame resistance as measured by the UL 94 Test for Flammability of Plastics.
18. The battery potting composition of claim 17 , wherein the liquid flame retardant component is present in an amount of at least 20 wt. %, based on the total weight of the potting composition.
19. The battery potting composition of claim 17 , wherein the liquid flame retardant component is present in an amount of at least 30 wt. %, based on the total weight of the potting composition.
20. The battery potting composition of claim 17 , wherein the liquid flame retardant includes a phosphate ester.