Aluminum Hydroxide Polymer for EV Thermal Management
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Solution Overview
Problem
Current materials for electric vehicles require high thermal conductivity, electrical insulation, elasticity, self-extinguishing properties, and long-term dimensional stability, but existing polymer systems fail to meet these criteria simultaneously, especially in terms of processability and component complexity.
Innovation Solution
A polymerizable resin composition with high aluminum hydroxide loading (75% by weight) and a hardener composition with similar loading, combined with specific particle size distributions of aluminum hydroxide, enhance thermal conductivity while maintaining electrical insulation and elasticity, allowing for suitable viscosities for casting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermally conductive fillers are added to polymers to increase thermal conductivity, then thermal conductivity is improved, but electrical insulating properties deteriorate
Solution Approach 1:
The filler system is segmented into multiple particle size fractions (fine, medium, coarse, and very coarse aluminum hydroxide particles), creating a hierarchical structure that optimizes both thermal conductivity and electrical insulation by distributing fillers at different scales throughout the polymer matrix
Solution Approach 2:
A composite filler system is used consisting of aluminum hydroxide particles in four different size ranges combined with a polyol resin, creating a composite material that achieves high thermal conductivity (up to 1.2 W/mK) while maintaining electrical insulation properties through the polymer matrix
2Temperature
If high filler loading is used to increase thermal conductivity, then thermal conductivity is improved, but viscosity increases making processing difficult
Solution Approach 1:
The filler is segmented into four distinct particle size fractions (0.5-2 μm, 2-10 μm, 10-50 μm, and 50-200 μm), allowing high overall filler loading (70-90 wt%) while the size distribution prevents excessive viscosity by reducing particle-particle interactions and improving flow characteristics
Solution Approach 2:
The particle size distribution parameter is optimized with specific ranges for each fraction, and the polyol resin content is adjusted (10-30 wt%) to control viscosity, enabling high filler loading while maintaining processability for casting and molding operations
3Temperature
If epoxy resin systems with aluminum oxide particles are used to achieve thermal conductivity, then thermal conductivity is improved, but elasticity and damping effect deteriorate
Solution Approach 1:
The patent replaces expensive epoxy resin systems with a polyol-based polymer system that, while having different inherent properties, achieves the required performance through high filler loading and optimized particle size distribution, providing the necessary elasticity and damping for automotive applications
Solution Approach 2:
A composite system is created using polyol resin combined with aluminum hydroxide filler in specific ratios (70-90 wt% filler), producing a material that exhibits both the thermal conductivity needed for battery cooling and the elasticity required for vibration damping in electric vehicles
4Reliability
If multiple different components are used to meet all requirements, then performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The aluminum hydroxide filler serves multiple functions simultaneously: it provides thermal conductivity for battery cooling, maintains electrical insulation, contributes to flame retardancy, and enables dimensional stability, eliminating the need for separate additives for each function
Solution Approach 2:
A composite material system is developed where polyol resin and aluminum hydroxide filler work together to provide multiple required properties (thermal conductivity, electrical insulation, elasticity, flame retardancy, dimensional stability) in a single formulation, reducing manufacturing complexity
5Ease of manufacture
If previously prepared mixtures of resin and filler are used, then production is simplified, but long-term stability deteriorates due to settling and reactivity
Solution Approach 1:
The filler is provided as separately stored fractions of different particle sizes that are mixed immediately before use, preventing settling and reactivity issues associated with pre-mixed systems while maintaining production simplicity through a standardized mixing procedure
Solution Approach 2:
The filler fractions are pre-classified into specific size ranges and stored separately in ready-to-use forms, allowing rapid mixing before application without compromising long-term storage stability, as each fraction remains stable in its separate storage
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 resulting polyurethane polymers exhibit high thermal conductivity, excellent electrical insulation, self-extinguishing properties, and long-term dimensional stability, making them suitable for electric vehicles with improved processability and reduced component complexity.
Implementation Method 1
materials with an extremely complex requirement profile are required... sufficient thermal conductivity, for example to dissipate heat that occurs during the charging process
Implementation Method 2
polymerizable resin composition comprising one or more polymerizable resin components... polyols, the polyamines and mixtures thereof
Data Source
AI summary
The present invention relates to a polymerizable resin composition which comprises the following, namely one or more polymerizable resin components selected from the group consisting of the polyols, the polyamines and mixtures thereof, in particular the polyether polyols, the polyester polyols, and the polybutadiene polyols, aluminium hydroxide, and also optionally other auxiliaries, for example wetting and dispersing additives, dyes, pigments, desiccants, fillers, polyalcohols, butanediol, hexanediol, antifoams, antisettling agents, plasticizers such as phosphates and catalysts. The resin composition contains, based on 100% by weight of the resin composition, at least 75% by weight, and in particular from 75 to 85% by weight, of aluminium hydroxide. The invention further relates to corresponding hardener compositions, polymers and filler mixtures.