FLAME RETARDANT COMPOSITIONS, COMPOUNDS, AND METHODS OF MAKING
A composition configured to cure to form a foam compound exhibiting at least a V2 level flame resistance as measured by the UL 94 Test for Flammability of Plastics, when measured with a sample of the foam compound having a thickness of no greater than one millimeter.
1 - 15 . (canceled)
16 . A potting compound comprising:
a polyurethane foam,
wherein the polyurethane foam exhibits at least a V2 level flame resistance as measured by the UL 94 Test for Flammability of Plastics when tested with a portion of the polyurethane foam having a length of no greater than 150 mm, a width of no greater than 13 mm, and a thickness of no greater than one mm, and
wherein a portion of the polyurethane foam having a thickness of no greater than 3.2 mm and having been subjected to the Burn Test exhibits a compressive strength of at least 20 psi when measured with the Foam Integrity Test.
17 . The potting compound of claim 16 , wherein the polyurethane foam exhibits at least a V1 level flame resistance as measured by the UL 94 Test for Flammability of Plastics when tested with a portion of the polyurethane foam having a length of no greater than 150 mm, a width of no greater than 13 mm, and a thickness of no greater than one mm.
18 . The potting compound of claim 16 , wherein the polyurethane foam exhibits at least a V0 level flame resistance as measured by the UL 94 Test for Flammability of Plastics when tested with a portion of the polyurethane foam having a length of no greater than 150 mm, a width of no greater than 13 mm, and a thickness of no greater than one mm.
19 . The potting compound of claim 16 , wherein a portion of the polyurethane foam having a thickness of no greater than 3.2 mm and having been subjected to the Burn Test exhibits a percent change in the modulus of no greater than 80% when measured by the Foam Integrity Test.
20 . The potting compound of claim 16 , wherein the polyurethane foam includes at least one % by weight a flame retardant component comprising expanded graphite, based on the total weight of the composition.
21 . The potting compound of claim 16 , wherein the polyurethane foam includes at least two % by weight a flame retardant component comprising expanded graphite, based on the total weight of the composition.
22 . The potting compound of claim 16 , wherein the polyurethane foam is formed from a composition having a viscosity of no greater than 2000 cp at any time within two minutes after all components of the composition have been combined.
23 . A battery module comprising:
an electric cell potted in a potting compound comprising a polyurethane foam,
wherein the polyurethane foam exhibits at least a V1 level flame resistance as measured by the UL 94 Test for Flammability of Plastics when tested with a portion of the polyurethane foam having a length of no greater than 150 mm, a width of no greater than 13 mm, and a thickness of no greater than one mm.
24 . The battery module of claim 23 wherein a portion of the polyurethane foam having a thickness of no greater than 3.2 mm and having been subjected to the Burn Test exhibits a percent change in the modulus of no greater than 80% when measured by the Foam Integrity Test.
25 . The battery module of claim 23 wherein, with a portion of the polyurethane foam having a length of no greater than 150 mm, a width of no greater than 13 mm, and a thickness of no greater than one mm, at least 60% of the portion of the polyurethane foam remains after the portion of polyurethane foam is subjected to the Foam Core Integrity Test.
26 . The battery module of claim 23 wherein a portion of the polyurethane foam subjected to the Burn Test exhibits a compressive strength of at least 20 psi when measured with the Foam Integrity Test using a sample of the polyurethane foam having a thickness of no greater than 3.2 millimeter.
27 . The battery module of claim 23 wherein the polyurethane foam exhibits at least a V0 level flame resistance as measured by the UL 94 Test for Flammability of Plastics when tested with a portion of the polyurethane foam having a length of no greater than 150 mm, a width of no greater than 13 mm, and a thickness of no greater than 1.6 mm.
28 . The battery module of claim 23 wherein the polyurethane foam exhibits at least a V0 level flame resistance as measured by the UL 94 Test for Flammability of Plastics when tested with a sample of the polyurethane foam having a length of no greater than 150 mm, a width of no greater than 13 mm, and a thickness of no greater than one mm.
29 . The battery module of claim 23 wherein the polyurethane foam includes at least one % by weight a flame retardant component comprising expandable graphite, based on the total weight of the composition.
30 . A battery module comprising:
an electric cell potted in a potting compound comprising a polyurethane foam,
wherein the polyurethane foam includes at least one % by weight a flame retardant component comprising expandable graphite, based on the total weight of the composition, and
wherein the polyurethane foam exhibits at least a V2 level flame resistance as measured by the UL 94 Test for Flammability of Plastics when tested with a sample of the polyurethane foam having a length of no greater than 150 mm, a width of no greater than 13 mm, and a thickness of no greater than one mm.
31 . The battery module of claim 30 wherein the polyurethane foam exhibits at least a V1 level flame resistance as measured by the UL 94 Test for Flammability of Plastics when tested with a sample of the polyurethane foam having a length of no greater than 150 mm, a width of no greater than 13 mm, and a thickness of no greater than one mm.
32 . The battery module of claim 30 wherein the polyurethane foam exhibits at least a V0 level flame resistance as measured by the UL 94 Test for Flammability of Plastics when tested with a sample of the polyurethane foam having a length of no greater than 150 mm, a width of no greater than 13 mm, and a thickness of no greater than one mm.
33 . The battery module of claim 30 wherein, with a portion of the polyurethane foam having a length of no greater than 150 mm, a width of no greater than 13 mm, and a thickness of no greater than one mm, at least 60% of the portion of the polyurethane foam remains after the portion of polyurethane foam is subjected to the Foam Core Integrity Test.
34 . The battery module of claim 30 wherein a portion of the polyurethane foam having a thickness of no greater than 3.2 mm and having been subjected to the Burn Test exhibits a percent change in the modulus of no greater than 80% when measured by the Foam Integrity Test.
35 . The battery module of claim 30 wherein the polyurethane foam is formed from a composition that is configured to flow under its own weight and settle at a substantially level height around, and in direct contact with an outer surface of, the electric cell before curing to foam the potting compound.