Thermally Conductive Acrylic Sheet With High Adhesion for Battery Modules
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Solution Overview
Problem
Thermally conductive sheets used in battery modules face a trade-off between achieving high thermal conductivity and maintaining sufficient adhesive strength, as increasing thermal conductivity often reduces adhesive strength due to lower binder resin content and crosslinking density, affecting environmental and thermal resistance.
Innovation Solution
A thermally conductive acrylic sheet is developed using a composition comprising an acrylic resin, a tackifying resin with hydrogenated rosin ester, an inorganic filler, and a photoinitiator, which is coated with a silane coupling agent and photocured, resulting in a solvent-free sheet with high adhesive strength, thermal conductivity, and elastic restoring force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the content of thermally conductive filler is increased to enhance thermal conductivity, then thermal conductivity is improved, but the content of binder resin is reduced, making it difficult to obtain high adhesive strength
Solution Approach 1:
The patent changes the molecular weight parameter of the binder resin from low to high, and introduces crosslinking density as a new parameter to control. By using high molecular weight binder resin with controlled crosslinking density, the system achieves both high thermal conductivity (from filler content) and high adhesive strength (from resin properties), resolving the trade-off between these two parameters.
Solution Approach 2:
The patent creates a composite material system consisting of thermally conductive filler particles dispersed in a high molecular weight binder resin matrix with controlled crosslinking. This composite structure allows the filler to provide thermal conductivity while the resin matrix provides adhesive strength, enabling both functions to coexist without compromising either property.
2Strength
If a binder resin with low molecular weight monomer crosslinking is used to increase adhesive strength, then adhesive strength is improved, but the crosslinking density becomes low, reducing environmental resistance, thermal resistance, and elastic restoring force
Solution Approach 1:
The patent changes the molecular weight parameter from low to high, and introduces crosslinking density as a controllable parameter. By using high molecular weight binder resin with optimized crosslinking density, the system achieves high adhesive strength while simultaneously improving environmental resistance, thermal resistance, and elastic restoring force, resolving the contradiction between strength and reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The thermally conductive acrylic sheet exhibits enhanced adhesive strength, thermal conductivity, and environmental resistance, effectively addressing the heat dissipation needs of battery modules and other electronic devices while maintaining structural integrity.
Implementation Method 1
coating the thermally conductive acrylic composition on a release film and photocuring it
Implementation Method 2
a thermally conductive acrylic sheet capable of exhibiting high adhesive strength while having excellent thermal conductivity
Data Source
AI summary
Since the thermally conductive acrylic sheet according to the embodiment is prepared from a thermally conductive acrylic composition containing a tackifying resin of a specific composition and a high content of an organic filler, it can have high adhesive strength with excellent thermal conductivity. Accordingly, the thermally conductive acrylic sheet according to the embodiment can be advantageously applied to various fields that require heat dissipation characteristics.