Resin Composition

Abstract

A resin composition, a method for manufacturing the same and a use thereof are provided. The resin composition provides excellent thixotropy while having one or more excellent properties selected from thermal conductivity, adhesiveness, insulation properties, tensile characteristics, hardness and flame retardancy.

Claims

1. A resin composition, comprising: a curable resin or a curing agent; and particles, wherein the particles have a change rate of a D50 particle diameter in a range of −95% to −80% after milling with zirconium beads having a particle diameter of 1 mm for 20 hours.

2. The resin composition according to claim 1, wherein the particles have a change rate of a D10 particle diameter in a range of −85% to −70% after milling with the zirconium beads having the particle diameter of 1 mm for 20 hours.

3. The resin composition according to claim 1, wherein the particles have a change rate of a D90 particle diameter in a range of −95% to −80% after milling with the zirconium beads having the particle diameter of 1 mm for 20 hours.

4. The resin composition according to claim 1, wherein the curable resin is a polyol compound and the curing agent is an isocyanate compound.

5. The resin composition according to claim 1, wherein the particles have the D50 particle diameter in a range of 1 to 10 μm.

6. The resin composition according to claim 5, wherein the particles have a ratio (D90/D50) of a D90 particle diameter to the D50 particle diameter in a range of 1.5 to 5.

7. The resin composition according to claim 5, wherein the particles have a ratio (D50/D10) of the D50 particle diameter to a D10 particle diameter in a range of 3.5 to 6.

8. The resin composition according to claim 1, further comprising a thermally conductive filler.

9. The resin composition according to claim 1, wherein the resin composition has a thixotropic index value of 1 to 4.

10. A resin composition, comprising: a curable resin; a curing agent; and particles, wherein the particles have a change rate of a D50 particle diameter in a range of −95% to −80% after being milled with zirconium beads having a particle diameter of 1 mm for 20 hours.

11. A method for preparing a resin composition, comprising: mixing a curable resin or a curing agent with particles, wherein the particles have a change rate of a D50 particle diameter in a range of −95% to −80% after being milled by zirconium beads having a particle diameter of 1 mm for 20 hours.

12. The method for preparing a resin composition according to claim 11, comprising: forming a mixture of the curable resin or the curing agent; and the particles with a first thermally conductive filler; and mixing the mixture with a second thermally conductive filler having an average particle diameter larger than that of the first thermally conductive filler.

13. A battery module, comprising: a module case having a top plate, a bottom plate, and sidewalls; a plurality of battery cells; and a resin layer, wherein an inner space is formed by the top plate, the bottom plate and the sidewalls; wherein the plurality of battery cells is in the inner space of the module case, wherein the resin layer comprises the resin composition of claim 1 and is in contact with the plurality of battery cells and the bottom plate or the sidewall.

14. A battery pack, comprising two or more battery modules of claim 13, wherein the two or more battery modules are electrically connected to each other.

15. A vehicle comprising the battery pack of claim 14.

16. A battery module, comprising: a module case having a top plate, a bottom plate, and sidewalls; a plurality of battery cells; and a resin layer, wherein an inner space is formed by the top plate, the bottom plate and the sidewalls; wherein the plurality of battery cells is in the inner space of the module case, wherein the resin layer comprises the resin composition of claim 10 and is in contact with the plurality of battery cells and the bottom plate or the sidewall.

Description

DESCRIPTION OF DRAWINGS

[0121] FIG. 1 shows an exemplary module case applicable in the present application.

[0122] FIG. 2 schematically shows a form in which battery cells are housed in a module case.

[0123] FIG. 3 schematically shows an exemplary bottom plate in which injection holes and observation holes are formed.

[0124] FIGS. 4 and 5 schematically show a structure of an exemplary battery module.

[0125] FIG. 6 is a view showing a change in particle size distribution of particles.

MODE FOR INVENTION

[0126] Hereinafter, the present application will be described in detail through examples, but the scope of the present application is not limited by the following examples.

[0127] 1. Particle Size Distribution of Particles

[0128] The particle size distribution of the particles (FR-119L) applied in the examples was evaluated by a laser analysis method. It was evaluated in a standard manner by applying a particle size distribution analyzer (PSA) (Model Mastersizer 300, Malvem Instruments LTD) as a measuring instrument. The manner uses lasers, where the incident lasers are scattered, transmitted and absorbed by particles and particularly, among the scattered light, diffracting, refracting and reflecting light exists. In some cases, a portion of the absorbed light is also emitted as light with a different wavelength. These phenomena occur simultaneously and multiply, where in the standard manner using the measuring instrument, the degree of light scattering is detected and the particle size distribution is measured as such. In the measurement methods, there are a wet method for measuring it by dispersing particles in a solvent, and a dry method for measuring it in a powder state, where in the present application, the wet method was applied. Ethanol was applied as the solvent, and the dispersion concentration was in the range of approximately 1 to 5 weight %.

[0129] 2. Evaluation of Particle Size Distribution after Milling

[0130] The particles (FR-119L) applied in the examples and zirconia beads having a diameter of 1 mm were dispersed in ethanol, and then milled by shaking at a speed of 200 RPM. The milling was performed for 20 hours, and when mixing, the total volume of the zirconia beads was mixed so that it was set to a level of ⅓ or so relative to the total volume of the flame retardant. After the milling, the mixture was washed with ethanol to separate the zirconia beads, and then the particle size distribution of the particles was measured in the same manner as described above.

[0131] 3. Viscosity of Resin Composition

[0132] The viscosity of the resin composition can be measured using an HB type viscometer. Here, it is measured while changing the shear rate from 0.01/s to 10.0/s with the HB type viscometer. Unless otherwise specified, the viscosity value is a value at a shear rate of 2.5/s, and the thixotropic index is the ratio of the viscosities at the point of 0.1/s and the point of 1.0/s.

EXAMPLE 1

[0133] Specific details of components applied during preparation of a resin composition were summarized below, and the method of preparing the resin composition using them was as follows, and mixing in the following preparation method was performed with a planetary mixer. Also, in the following preparation method, a curable resin is divided into three times in total and dividedly added, and finally, when the amount of the curable resin present in the resin composition is 100 parts by weight, the weight ratio of the primary, secondary and tertiary curable resins which are added is approximately 50 to 55:25:25 to 20 (primary:secondary:tertiary). Furthermore, in the following, an alumina filler was mixed in an amount of approximately 900 parts by weight relative to 100 parts by weight of the total curable resin component, where the weight ratio of the alumina filler having average particle diameters (D50) of approximately 2 μm, 20 μm and 40 μm was set to approximately 3:3:4 or so (2 μm:20 μm:40 μm).

[0134] First, as a first step, the following curable resin was mixed with a catalytic amount of catalyst (addition of the primary curable resin). Thereafter, the following dispersant and liquid flame retardant were mixed in an appropriate ratio into the mixture.

[0135] Then, a spherical alumina filler (first thermally conductive filler) having an average particle diameter (D50) of approximately 2 μm and the following particles (FR-119L) were mixed into the mixture. Here, the particles (FR-119L) were mixed in about 15 parts by weight.

[0136] Then, a mixture of the same curable resin as contained in the mixture and a spherical alumina filler (second thermally conductive filler) having an average particle diameter (D50) of approximately 20 μm was further mixed into the mixture (addition of the secondary curable resin).

[0137] Then, a mixture of the same curable resin as contained in the mixture and a spherical alumina filler (third thermally conductive filler) having an average particle diameter (D50) of approximately 40 μm was further mixed into the mixture (addition of the tertiary curable resin) and defoamed in vacuum to prepare a resin composition.

[0138] In the resin composition prepared as described above, the viscosity (shear rate: based on 2.5/s) at room temperature was about 230,000 kcP, and the thixotropic index was about 2 or so.

[0139] <Resin Composition Components>

[0140] Curable resin: polyol compound obtained by esterification of butanediol and caprolactone in a weight ratio of 1:2.78 (butanediol:caprolactone)

[0141] Catalyst: DBTDL (dibutyltin dilaurate) (Songwon Industries, TL-100)

[0142] Dispersant: DISPERBYK-111 (BYK).

[0143] Liquid flame retardant: Liquid phosphorus flame retardant (Oceanchem, resorcinol bis(diphenyl phosphate)).

[0144] Particles: Particulate phosphorus flame retardant (aluminum hydroxymethylphenylphosphinate) (X-Guard FR-119L)

[0145] The particle size distribution changes of the particles before and after the above-described milling were summarized in Table 1 below, and such a particle size distribution change curve was shown in FIG. 6. In FIG. 6, the arrow direction is shown in a direction proceeding from the curve before milling to the curve after milling.

TABLE-US-00001 TABLE 1 D10 particle D50 particle D90 particle diameter (μm) diameter (μm) diameter (μm) Before milling 0.534 2.33 6.93 After milling 0.108 0.235 0.491

COMPARATIVE EXAMPLE 1

[0146] A resin composition was prepared in the same manner as in Example 1, except that particles were not applied. In this case, the thixotropic index at the initial stage of preparation was approximately 1 or so, whereby there was almost no thixotropy, and the uniform mixing of the curable resin and the filler was not achieved due to sedimentation of the filler or the like over time.