Thermally conductive two component resin based on carbodiimide chemistry

A thermally conductive two-component resin based on carbodiimide chemistry addresses the challenges of high thermal conductivity, flame retardancy, and low electric conductivity in battery modules, achieving effective performance and processability.

WO2025067942A1 Publication Date: 2025-04-03BASF SE
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Patent Information

Application Number
PCT/EP2024/075884
Authority / Receiving Office
WO · WO
Patent Type
Applications
Current Assignee / Owner
Priority Date
2023-09-25
Filing Date
2024-09-17
Publication Date
2025-04-03

AI Technical Summary

Technical Problem

Existing thermally conductive resins used in battery modules face challenges in achieving high thermal conductivity, flame retardancy, and low electric conductivity while maintaining mechanical properties and processability, especially under conditions of external shocks and temperature variations.

Method used

A thermally conductive two-component resin based on carbodiimide chemistry is developed by mixing a carbodiimide component with a carbodiimide reactive component, incorporating surface-modified aluminum tri-hydroxide or aluminum oxide fillers, and optimizing the molar ratio and filler content to achieve desired properties.

Benefits of technology

The resulting resin exhibits a thermal conductivity of at least 0.8 W/mK, excellent flame retardancy, low electric conductivity, and maintained mechanical properties such as shear strength, while also ensuring good processability with low viscosity and squeeze flow.

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Abstract

The present invention relates to a process for the production of a thermally conductive resin obtained by mixing a carbodiimide component (A) and at least one carbodiimide reactive component (B) to form a reaction mixture and allowing the reaction mixture to cure, wherein the carbodiimide component (A) comprises at least one carbodiimide (a1), optionally at least one thinner (a2), at least one filler selected from the group consisting of at least one surface modified aluminum tri-hydroxide, at least one aluminum oxide or mixtures thereof (a3); and the carbodiimide reactive component (B) comprises at least one organic compound comprising at least 2 hydrogen atoms reactive towards carbodiimide groups (b1) and at least one filler selected from the group consisting of at least one surface modified aluminum tri-hydroxide, at least one aluminum oxide or mixtures thereof (b2), and optionally at least one catalyst (b3), wherein the molar ratio of carbodiimide groups in the carbodiimide compound (A) to reactive hydrogen atoms in component (B) is in the range of from 1:2 to 2:1, the content of the at least one filler (a3) is from 70 to 95 % by weight, based on the total weight of the carbodiimide component (A) and the content of the at least one filler (b2) is from 70 to 95 % by weight, based on the total weight of the carbodiimide reactive component (B). The present invention further relates to a two component resin composition comprising a carbodiimide component (A) and at least one carbodiimide reactive component (B) according to the invention, a thermal conductive resin obtained by a process according to the invention and a battery module comprising a module case having a top plate, a bottom plate and sidewalls, wherein an inner space is formed by the top plate, the bottom plate, and the sidewalls; a plurality of battery cells existing in the inner space of the module case; and a resin layer formed by a process according to the present invention, wherein the reaction mixture is cured in contact with the plurality of battery cells.
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