CN109082883A - 防火绝缘复合薄膜及其制造方法 - Google Patents
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Abstract
本发明涉及一种防火绝缘复合薄膜及其制造方法。本发明的防火绝缘复合薄膜用于储能装置内。本发明的防火绝缘复合薄膜包含织布基材以及碱金属硅酸盐薄膜：织布基材可以由玻璃纤维、Nomex纤维、Kevlar纤维、PBO纤维或PMMA纤维所织成；碱金属硅酸盐薄膜形成以被覆织布基材的上表面。本发明提供的防火绝缘复合薄膜具有高破坏电压、高热传系数、高介电常数、低密度以及优良的机械性质。
Description
技术领域
本发明涉及一种防火绝缘复合薄膜及其制造方法，尤其涉及一种具有高破坏电压、高热传系数、高介电常数、低密度、优良机械性质的防火绝缘复合薄膜及其制造方法。
背景技术
绝缘薄膜常见于应用在储能装置内，例如，锂电池、超级电容等。以磷酸锂铁电池为例，目前商用的绝缘薄膜为聚丙烯(Polypropylene,PP)、聚乙烯(Polyethylene,PE)多孔性薄膜且表面涂布SiO2或Al2O3颗粒的复合绝缘薄膜。
目前提升电池或超级电容等储能装置的效能(例如，充电电压、减少整体重量、延长元件寿命等)的研究工作，多见于电极材料、电解质的研发。然而，对于影响储能装置的效能甚重的绝缘薄膜研究较少。绝缘薄膜的改善仍存有很大的空间，例如，目前绝缘薄膜具有的低破坏电压、低热传系数、低介电常数、高密度、差的机械性质等缺点，并且不防火。
发明内容
因此，本发明所欲解决的技术问题在于提供一种具有高破坏电压、高热传系数、高介电常数、低密度、优良机械性质的防火绝缘复合薄膜及其制造方法。
本发明提供一较佳具体实施例的防火绝缘复合薄膜用于储能装置内。本发明的防火绝缘复合薄膜包含织布基材以及第一碱金属硅酸盐薄膜。织布基材具有上表面以及下表面。织布基材可以由玻璃纤维、Nomex纤维、Kevlar纤维、PBO纤维、聚甲基丙烯酸甲酯(Polymethyl methacrylate,PMMA)纤维或其他耐燃纤维所织成。第一碱金属硅酸盐薄膜形成以被覆织布基材的上表面。
进一步，本发明的防火绝缘复合薄膜还包含第二碱金属硅酸盐薄膜。第二碱金属硅酸盐薄膜形成以被覆织布基材的下表面。
在一具体实施例中，第一碱金属硅酸盐薄膜以及第二碱金属硅酸盐薄膜皆可以由包含钾的硅酸盐所形成，并且包含钾的硅酸盐的硅/钾比例范围为2.0～2.5。
在另一具体实施例中，第一碱金属硅酸盐薄膜以及第二碱金属硅酸盐薄膜皆可以由包含钠的硅酸盐所形成，并且包含钠的硅酸盐的硅/钠比例范围为1.8～2.8。
在一具体实施例中，本发明的防火绝缘复合薄膜的破坏电压大于或等于7.10kV，本发明的防火绝缘复合薄膜的热传导系数大于或等于3w/mK。
根据本发明的一较佳具体实施例的制造防火绝缘复合薄膜的方法，首先，是制备织布基材。织布基材具有上表面以及下表面。织布基材可以由玻璃纤维、Nomex纤维、Kevlar纤维、PBO纤维、PMMA纤维或其他耐燃纤维所织成。接着，本发明的方法以碱金属硅酸盐液体涂布在织布基材的上表面以及下表面上。最后，本发明的方法对已涂布碱金属硅酸盐液体的织布基材进行烘烤制程，即在织布基材的上表面上形成第一碱金属硅酸盐薄膜且在织布基材的下表面上形成第二碱金属硅酸盐薄膜，进而完成防火绝缘复合薄膜。
在一具体实施例中，烘烤制程的温度范围介于85℃至130℃。
与现有技术不同，根据本发明的防火绝缘复合薄膜具有高破坏电压、高热传系数、高介电常数、低密度、优良机械性质，并且防火。
关于本发明的优点与精神可以通过以下的发明详述及附图得到进一步的了解。
附图说明
图1是根据本发明的一较佳具体实施例的防火绝缘复合薄膜的剖视图。
附图标记说明：
1、防火绝缘复合薄膜； 10、织布基材；
102、上表面； 104、下表面；
12、第一碱金属硅酸盐薄膜； 14、第二碱金属硅酸盐薄膜；
16、高分子材料层。
具体实施方式
请参阅图1，图1的剖视图示出了根据本发明的一较佳具体实施例的防火绝缘复合薄膜1。本发明的防火绝缘复合薄膜1用于储能装置内，例如，电池、超级电容等。
如图1所示，本发明的防火绝缘复合薄膜1包含织布基材10以及第一碱金属硅酸盐薄膜12。织布基材10具有上表面102以及下表面104。织布基材10可以由玻璃纤维、Nomex纤维、Kevlar纤维、聚对苯撑苯并二嗯唑纤维(Poly-p-phenylene benzo-bisoxazazolefiber,简称PBO纤维)、PMMA纤维或其他耐燃纤维所织成。第一碱金属硅酸盐薄膜12形成以被覆织布基材10的上表面102。织布基材10本质上具有多个孔隙。Nomex纤维为聚间苯二甲酸二胺纤维的商品名称(杜邦公司生产)。Kevlar纤维为芳香聚酰胺类合成纤维的商品名称(杜邦公司生产)。
同样如图1所示，进一步，本发明的防火绝缘复合薄膜1还包含第二碱金属硅酸盐薄膜14。第二碱金属硅酸盐薄膜14形成以被覆织布基材10的下表面104。
在一具体实施例中，第一碱金属硅酸盐薄膜12以及第二碱金属硅酸盐薄膜14皆可以由包含钾的硅酸盐所形成，并且包含钾的硅酸盐的硅/钾比例范围为2.0～2.5。
在另一具体实施例中，第一碱金属硅酸盐薄膜12以及第二碱金属硅酸盐薄膜14皆可以由包含钠的硅酸盐所形成，并且包含钠的硅酸盐的硅/钠比例范围为1.8～2.8。
一般碱金属硅酸盐的分子式为R2O·nSiO2，式中R2O为碱金属氧化物，n为二氧化硅与碱金属氧化物摩尔数的比值，称为碱金属硅酸盐的模数。须强调的是，一般商用碱金属硅酸盐的模数在1.5-3.5之间，显见地本发明所采用的包含钾的硅酸盐以及包含钠的硅酸盐与一般商用的碱金属硅酸盐不同。
同样如图1所示，进一步，本发明的防火绝缘复合薄膜1还包含高分子材料层16。高分子材料层16形成以被覆第二碱金属硅酸盐薄膜14。储能装置的最外层绝缘薄膜通常还需要执行后续处理，例如，印刷、贴附其他材料层等。上述高分子材料层16适于执行后续处理。在一具体实施例中，高分子材料层16可以由聚乙烯对苯二甲酸酯(PolyethyleneTerephthalate，PET)、高密度聚乙烯(high density Polyethylene,HDPE)、PP、聚乳酸(Polylactic Acid,PLA)、聚氯乙烯(Polyvinylchloride,PVC)、聚萘二甲酸乙二醇酯(Polyethylene-naphthalate,PEN)或其他合适的高分子材料所形成。
根据本发明的一较佳具体实施例的制造如图1所示的防火绝缘复合薄膜1的方法，首先，是制备织布基材10。织布基材10具有上表面102以及下表面104。织布基材10可以由玻璃纤维、Nomex纤维、Kevlar纤维、PBO纤维、PMMA纤维或其他耐燃纤维所织成。
接着，本发明的方法以碱金属硅酸盐液体涂布在织布基材10的上表面102以及下表面104上。在一具体实施例中，碱金属硅酸盐液体可以通过浸涂制程或滚涂制程(但并不以此为限)涂布在织布基材10的上表面102以及下表面104上。
最后，本发明的方法是对已涂布碱金属硅酸盐液体的织布基材10进行烘烤制程，即在织布基材10的上表面102上形成第一碱金属硅酸盐薄膜12且在织布基材10的下表面104上形成第二碱金属硅酸盐薄膜14，进而完成防火绝缘复合薄膜1。
在一具体实施例中，烘烤制程的温度范围介于85℃至130℃。在一范例中，烘烤制程包含三个阶段：第一阶段：烘烤温度为85℃，维持5秒；第二阶段：烘烤温度为130℃，维持15秒；第三阶段：烘烤温度为85℃，维持5秒。
在一具体实施例中，本发明的防火绝缘复合薄膜1适合利用卷对卷成型制程(roll-to-roll process)来制造。
进一步，本发明的方法形成高分子材料层16。高分子材料层16形成以被覆第二碱金属硅酸盐薄膜14。在一具体实施例中，高分子材料层16可以由聚乙烯对苯二甲酸酯(Polyethylene Terephthalate，PET)、高密度聚乙烯(high density Polyethylene,HDPE)、PP、聚乳酸(Polylactic Acid,PLA)、聚氯乙烯(Polyvinylchloride,PVC)、聚萘二甲酸乙二醇酯(Polyethylene-naphthalate,PEN)或其他合适的高分子材料所形成。在一具体实施例中，高分子材料层16可以通过滚涂制程(但并不以此为限)被覆第二碱金属硅酸盐薄膜14上。
以下为本发明的防火绝缘复合薄膜1采用玻璃纤维织成的织布基材10进行多种测试所得结果。
本发明的防火绝缘复合薄膜1的整体厚度范围为10μm～50μm。本发明的防火绝缘复合薄膜12的一厚度为20μm的样本遵循ASTM D149-09测试规范，测得其破坏电压为7.13kV。在实际应中，采用破坏电压高于7.10kV的本发明的防火绝缘复合薄膜12的储能装置能大幅提升充电电压，仍保有安全性。
本发明的防火绝缘复合薄膜1遵循ASTM D792-13Method A测试规范，测得其比重为2.03。足以证实，本发明的防火绝缘复合薄膜1具有低密度。
本发明的防火绝缘复合薄膜1遵循ASTM D257-07测试规范，测得其表面阻抗为4.41×105Ω。
本发明的防火绝缘复合薄膜1遵循ASTM D638-14(Type IV，V＝5mm/min)测试规范，测得其抗拉强度为1446(kgf/cm2)，其伸长率为1.16％。足以证实，本发明的防火绝缘复合薄膜1具有高强度。
本发明的防火绝缘复合薄膜1遵循ASTM D150-11测试规范，测得其介电常数为12.3，其逸散因子为0.387。足以证实，本发明的防火绝缘复合薄膜1具有高介电常数。
本发明的防火绝缘复合薄膜1遵循ASTM D5470-01测试规范，测得其热传导系数为3w/mK。足以证实，本发明的防火绝缘复合薄膜1具有高热传导系数。
本发明的防火绝缘复合薄膜1遵循UL 94(2013)测试规范，测得其点火燃烧后的余焰时间为0秒，也就是说其通过燃烧测试。此外，本发明的防火绝缘复合薄膜1经测试其无玻璃转换温度。本发明采用其他纤维织成的织布基材10也耐燃。
综上所述，能让本领域技术人员清楚了解根据本发明所采用的包含钾的硅酸盐以及包含钠的硅酸盐与一般商用的碱金属硅酸盐不同。并且，其光电转换效率较典型的PERC硅基光伏元件更加提升。与现有技术不同，根据本发明的防火绝缘复合薄膜具有高破坏电压、高热传系数、高介电常数、低密度、优良机械性质，并且防火。
通过以上较佳具体实施例的详述，希望能更加清楚描述本发明的特征与精神，而并非以上述所揭示的较佳具体实施例来对本发明的面向加以限制。相反地，其目的是希望能涵盖各种改变及具相等性的处于本发明所欲申请的专利保护范围之内。因此，本发明所申请的专利的保护范围应该根据上述的说明作最宽广的解释，以致使其涵盖所有可能的改变以及具相等性的安排。
Claims (10)
1.一种防火绝缘复合薄膜，用于一储能装置内，其特征在于，所述防火绝缘复合薄膜包含：
一织布基材，具有一上表面以及一下表面，所述织布基材由玻璃纤维、聚间苯二甲酸二胺纤维(Nomex纤维)、聚对苯二甲酰对苯二胺纤维(Kevlar纤维)、聚对苯撑苯并二嗯唑(Poly-p-phenylene benzo-bisoxazazole fiber,PBO)纤维以及聚甲基丙烯酸甲酯(Polymethyl methacrylate,PMMA)纤维所组成的群组中的一个所织成；以及
一第一碱金属硅酸盐薄膜，形成以被覆所述上表面。
2.根据权利要求1所述的防火绝缘复合薄膜，其特征在于，进一步包含一第二碱金属硅酸盐薄膜，形成以被覆所述下表面。
3.根据权利要求2所述的防火绝缘复合薄膜，其特征在于，所述第一碱金属硅酸盐薄膜以及所述第二碱金属硅酸盐薄膜皆由一包含钾的硅酸盐或一包含钠的硅酸盐所形成，所述包含钾的硅酸盐的一硅/钾比例范围为2.0～2.5，并且所述包含钠的硅酸盐的一硅/钠比例范围为1.8～2.8。
4.根据权利要求2所述的防火绝缘复合薄膜，其特征在于，进一步包含一高分子材料层，形成以被覆所述第二碱金属硅酸盐薄膜，并且所述高分子材料层由选自由聚乙烯对苯二甲酸酯(Polyethylene Terephthalate，PET)、高密度聚乙烯(high densityPolyethylene,HDPE)、聚丙烯(Polypropylene，PP)、聚乳酸(Polylactic Acid,PLA)、聚氯乙烯(Polyvinylchloride,PVC)以及聚萘二甲酸乙二醇酯(Polyethylene-naphthalate,PEN)所组成的群组中的一个所形成。
5.根据权利要求2所述的防火绝缘复合薄膜，其特征在于，所述防火绝缘复合薄膜具有一破坏电压以及一热传导系数，所述破坏电压大于或等于7.10kV，所述热传导系数大于或等于3w/mK。
6.一种制造防火绝缘复合薄膜的方法，所述防火绝缘复合薄膜用于一储能装置内，其特征在于，所述方法包含下列步骤：
制备一织布基材，所述织布基材具有一上表面以及一下表面，所述织布基材由选自由玻璃纤维、聚间苯二甲酸二胺纤维(Nomex纤维)、聚对苯二甲酰对苯二胺纤维(Kevlar纤维)、聚对苯撑苯并二嗯唑(Poly-p-phenylene benzo-bisoxazazole fiber,PBO)纤维以及聚甲基丙烯酸甲酯(Polymethyl methacrylate,PMMA)纤维所组成的群组中的一个所织成；
以一碱金属硅酸盐液体涂布所述上表面以及所述下表面；以及
对已涂布所述碱金属硅酸盐液体的所述织布基材进行一烘烤制程，即在所述上表面上形成一第一碱金属硅酸盐薄膜且在所述下表面上形成一第二碱金属硅酸盐薄膜进而完成所述防火绝缘复合薄膜。
7.根据权利要求6所述的方法，其特征在于，所述第一碱金属硅酸盐薄膜以及所述第二碱金属硅酸盐薄膜皆由一包含钾的硅酸盐或一包含钠的硅酸盐所形成，所述包含钾的硅酸盐的一硅/钾比例范围为2.0～2.5，并且所述包含钠的硅酸盐的一硅/钠比例范围为1.8～2.8。
8.根据权利要求6所述的方法，其特征在于，进一步包含下列步骤：
形成一高分子材料层，以被覆所述第二碱金属硅酸盐薄膜，其中所述高分子材料层由选自由聚乙烯对苯二甲酸酯(Polyethylene Terephthalate，PET)、高密度聚乙烯(highdensity Polyethylene,HDPE)、聚丙烯(Polypropylene，PP)、聚乳酸(Polylactic Acid,PLA)、聚氯乙烯(Polyvinylchloride,PVC)以及聚萘二甲酸乙二醇酯(Polyethylene-naphthalate,PEN)所组成的群组中的一个所形成。
9.根据权利要求6所述的方法，其特征在于，所述防火绝缘复合薄膜具有一破坏电压以及一热传导系数，所述破坏电压大于或等于7.10kV的，所述热传导系数大于或等于3w/mK。
10.根据权利要求6所述的方法，其特征在于，所述烘烤制程的一温度范围介于85℃至130℃。
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