Abstract: Provided are non-woven fibrous webs, methods and assemblies thereof. The non-woven fibrous web comprises a plurality of melt-blown fibers. The plurality of melt-blown fibers include a thermoplastic polymer blended with a phosphinate and/or polymeric phosphonate. The provided non-woven articles can afford a fine fiber diameter for enhanced acoustic insulation properties, dimensional stability, and superior flame-retardant properties when compared with conventional non-woven articles having similar fiber diameters.

Abstract: An assembly includes an enclosure including first and second regions spaced apart along a first direction, and a plurality of spaced apart acoustic baffles arranged along a second direction different from the first direction and disposed in the enclosure between the first and second regions. The plurality of spaced apart acoustic baffles includes adjacent first and second acoustic baffles. Each of the first and second acoustic baffles include an acoustically absorptive layer disposed on a sheet having a specific airflow resistance greater than 200 MKS Rayl. The first and second acoustic baffles define a channel therebetween. At least a portion of the channel extends along a longitudinal direction making an oblique angle with the first direction.

Abstract: Provided is a battery assembly that includes a housing, one or more battery cells electrically coupled to a busbar, the one or more battery cells and busbar being received in the housing. A non-woven core layer is disposed between the busbar and housing, the non-woven core layer comprising a plurality of fibers, the plurality of fibers includes a plurality of oxidized polyacrylonitrile fibers and a coating disposed thereon that binds the plurality of oxidized polyacrylonitrile fibers to each other. Advantageously, the provided assemblies can exhibit extremely high electrical resistance, thermal resistance, and very high dielectric breakdown voltage.

Abstract: Provided is an acoustic article and related methods of manufacture and use. The acoustic article includes a continuous layer having a first elastic stiffness, and a plurality of distributed masses disposed on a major surface of the continuous layer having a second elastic stiffness. The second elastic stiffness can be less than the first elastic stiffness to provide an acoustic metamaterial displaying an anti-resonance peak at a frequency below 800 Hz. The acoustic article can be made using efficient and scalable processes for manufacturing low frequency acoustic barrier materials.

Abstract: Provided is a battery assembly that includes an electrically-conductive housing (510A, 510B), one or more battery modules (512) electrically coupled to a busbar (522), the one or more battery modules and busbar being received in the housing. A non-woven core layer (506) is disposed between the busbar and electrically-conductive housing, the non-woven core layer comprising a plurality of fibers, the plurality of fibers comprising 60-100 wt % of oxidized polyacrylonitrile fibers. The non-woven core layer can exhibit a breakdown voltage of at least 0.9 kV at ambient conditions after exposure to 500° C. for 5 minutes.

Abstract: A ceramifiable composition comprises a crosslinked silicone matrix retaining stabilizing components. The stabilizing components comprise subcomponents: a) at least one of an aluminosilicate clay, aluminum oxide, or a hydrate thereof; b) at least one of phosphorus pentoxide, a polyphosphate, an inorganic phosphate salt, boron oxide, boric acid or a salt thereof; and c) at least one of an alkaline earth oxide, alkaline earth carbonate, or a hydrate thereof, and wherein heating the ceramifiable composition to a temperature between 600 and 1600 degrees Celsius, inclusive, results in a ceramified composition. An article including a layer of the ceramifiable composition and a method of making the same are also disclosed.

Abstract: A battery assembly comprises an assembly housing, a plurality of battery modules disposed within the assembly housing and electrically coupled to a busbar, and at least one ceramifiable pad disposed within the assembly housing. Each battery module comprises a plurality of individual cells disposed within a module housing. The at least one ceramifiable pad is disposed between at least one of: at least two of the individual cells, at least two of the battery modules, the busbar and the assembly housing, or at least one of the battery modules and the assembly housing. The ceramifiable pad comprises a ceramifiable composition. Heating the ceramifiable composition to a temperature between 600 and 1600° C., inclusive, results in a ceramified composition. Ceramifiable compositions and methods of making them are also disclosed.

Abstract: The provided articles and methods use a non-woven fibrous web containing 60-100 wt % of oxidized polyacrylonitrile fibers; and 0-40 wt % of reinforcing fibers having outer surfaces comprised of a polymer with a melting temperature of from 100° C. to 300° C. The non-woven fibrous web has an average bulk density of from 15 kg/m3 to 50 kg/m3, with the plurality of fibers substantially entangled along directions perpendicular to a major surface of the non-woven fibrous web. Optionally, the oxidized polyacrylonitrile fibers can have a crimped configuration. Advantageously, these articles can display a combination of low thermal conductivity, high tensile strength, and flame resistance.

Abstract: A nonwoven fibrous web and a method of making thereof. The nonwoven fibrous web includes greater than 0% but no greater than 30 wt % of a plurality of melt-blown fibers comprised of a crystalline (co)polymer; and at least 70 wt % of a plurality of randomly-oriented staple fibers, the plurality of randomly-oriented staple fibers including: at least 60 wt % of oxidized polyacrylonitrile fibers; and from 0 to 40 wt % of reinforcing fibers having an outer surface comprised of a (co)polymer with a melting temperature of from 100° C. to 350° C.; wherein the plurality of melt-blown fibers and the plurality of randomly-oriented staple fibers are bonded together to form a cohesive non-woven fibrous web.

Abstract: The provided articles and methods use a non-woven fibrous web containing 60-100 wt % of oxidized polyacrylonitrile fibers; and 0-40 wt % of reinforcing fibers having outer surfaces comprised of a polymer with a melting temperature of from 100° C. to 300° C. The non-woven fibrous web has an average bulk density of from 15 kg/m3 to 50 kg/m3, with the plurality of fibers substantially entangled along directions perpendicular to a major surface of the non-woven fibrous web. Optionally, the oxidized polyacrylonitrile fibers can have a crimped configuration. Advantageously, these articles can display a combination of low thermal conductivity, high tensile strength, and flame resistance.

Abstract: An assembly includes an enclosure including first and second regions spaced apart along a first direction, and a plurality of spaced apart acoustic baffles arranged along a second direction different from the first direction and disposed in the enclosure between the first and second regions. The plurality of spaced apart acoustic baffles includes adjacent first and second acoustic baffles. Each of the first and second acoustic baffles include an acoustically absorptive layer disposed on a sheet having a specific airflow resistance greater than 200 MKS Rayl. The first and second acoustic baffles define a channel therebetween. At least a portion of the channel extends along a longitudinal direction making an oblique angle with the first direction.

Abstract: Insulating articles, assemblies and methods are provided. The insulating articles include a core layer (101,201) containing a plurality of non-meltable fibers; and at least one reinforcement layer (102, 202) disposed on the core layer (101,201). The insulating article has tensile strength of at least 0.75 newtons/millimeter according to ASTM D822 and a tear strength of at least 2 newtons under ASTM D1938, wherein the insulating article has a surface electrical resistivity of at least 15 M-ohm at a relative humidity of 85% and temperature of 30° C., wherein the insulating article has an air flow resistance of up to 2000 MKS Rayls according to ASTM C522, and wherein the insulating article displays a UL94-V0 flammability rating.

Abstract: The present disclosure provides a high temperature, flame resistant and flexible coating composition based on alkali silicate and fluoropolymers. The coating can be used to bond a surface of a non-woven mat and seal the edges. The coating composition can be applied using a coating method on the surface and the edges of, for example, an inorganic fiber based non-woven mat.

Abstract: A composite film comprises first and second layers. The first layer comprises a first copolymer of monomers comprising tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride, wherein the first copolymer contains at least 35 mole percent of vinylidene fluoride monomer units. The second layer is disposed on the first layer, and comprises a second copolymer comprising 50 to 83 weight percent of ethylene monomer units and at least 17 weight percent of alkyl (meth)acrylate monomer units represented by the formula (I) wherein R1 is H or methyl, and each R2 is independently an alkyl group having from 1 to 4 carbon atoms. Methods of making the composite film and articles including it are also disclosed.

Abstract: A nonwoven fabric and a method of making thereof. The nonwoven fabric includes a plurality of randomly-oriented fibers, the plurality of randomly-oriented fibers including: at least 60 wt % of oxidized polyacrylonitrile fibers; and from to less than 40 wt % of reinforcing fibers having an outer surface comprised of a (co)polymer with a melting temperature of from 100° C. to 450° C.; and a fluoropolymer binder on the plurality of randomly-oriented fibers; wherein the plurality of randomly-oriented fibers is bonded together to form the nonwoven fabric, optionally wherein the nonwoven fabric has a thickness of one millimeter or less.

Abstract: Provided is a multilayer thermal insulator and related method that use a non-woven core layer comprising non-meltable and flame-resistant polymeric fibers. One or more scrims are disposed on the opposing major surfaces of the non-woven core layer, and a peripheral edge of the one or more scrims is either edge sealed or capable of being edge sealed to substantially encapsulate the non-woven core layer within the one or more scrims. Optionally, a binder is provided on the scrims or non-woven core layer to facilitate edge sealing. The provided insulators are essentially dust-free and capable of passing stringent flammability standards.

Abstract: A nonwoven fiber assembly. The nonwoven fiber assembly includes a nonwoven fibrous web including a plurality of discontinuous fibers; and a nonwoven fabric at least partially surrounding the nonwoven fibrous web; the nonwoven fabric including a plurality of randomly-oriented fibers, the plurality of randomly-oriented fibers comprising: at least 60 wt % of oxidized polyacrylonitrile fibers; and from 0 to less than 40 wt % of reinforcing fibers having an outer surface comprised of a (co)polymer with a melting temperature of from 100° C. to 450° C.; and a fluoropolymer binder on the plurality of randomly-oriented fibers.

Abstract: Provided are non-woven fibrous webs, methods and assemblies thereof. The non-woven fibrous web comprises a plurality of melt-blown fibers. The plurality of melt-blown fibers include a thermoplastic polymer blended with a phosphinate and/or polymeric phosphonate. The provided non-woven articles can afford a fine fiber diameter for enhanced acoustic insulation properties, dimensional stability, and superior flame-retardant properties when compared with conventional non-woven articles having similar fiber diameters.

Abstract: A fire protection article is provided that includes a fire barrier comprising a plurality of non-combustible fibers, and a passive thermal insulator coupled to the fire barrier and comprising a plurality of non-meltable fibers. Optionally, the fire protection article displays a time to break in the 1100° C. Break Strength Test of at least 10 seconds or a minimum tensile strength at 150° C. of at least 5 kPa. Optionally, the fire barrier comprises substantially continuous fibers that are mutually entangled. The fire barrier and passive thermal insulator can be mutually secured using a suitable polymeric binder, such a thermoplastic fluoropolymer binder. The combination of a relatively thin fire barrier with a comparatively thicker passive thermal insulator can provide thermal runaway protection in lithium-ion battery applications, structural integrity and a high degree of thermal insulation in the event of fire exposure.

Abstract: Provided is a multilayer thermal insulator and related method that use a non-woven core layer comprising non-meltable and flame-resistant polymeric fibers. One or more scrims are disposed on the opposing major surfaces of the non-woven core layer, and a peripheral edge of the one or more scrims is either edge sealed or capable of being edge sealed to substantially encapsulate the non-woven core layer within the one or more scrims. Optionally, a binder is provided on the scrims or non-woven core layer to facilitate edge sealing. The provided insulators are essentially dust-free and capable of passing stringent flammability standards.