Battery Module Polymer Housing for Lightweight Heat Dissipation

Solution Overview

Problem

Existing battery systems for electric vehicles face challenges with lithium-ion batteries, which are sensitive to temperature and require expensive and heavy conductive metals for heat management, while thermally conductive polymers often lack the necessary strength or are heat sensitive.

Innovation Solution

A battery module utilizing a polymer composition that includes a thermotropic liquid crystalline polymer and a thermally conductive filler, achieving high in-plane thermal conductivity of 3 W/m-K or more and a deflection temperature under load of 230° C. or more.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conductive metals are employed in the housing of lithium-ion battery modules to conduct heat away from the batteries, then thermal management effectiveness is improved, but cost and weight increase

Engineering Contradiction:

Improveheat conduction capabilityVSAvoidhousing weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The patent changes the material parameters by using a polymer matrix combined with thermally conductive fillers (such as aluminum oxide, aluminum nitride, boron nitride, or graphite) to achieve high thermal conductivity without the weight penalty of metals. The filler content is optimized to reach thermal conductivity of at least 3 W/m·K while maintaining polymer-based lightweight characteristics.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite materials by combining a polymer matrix with thermally conductive filler particles. This composite approach enables the housing to achieve metal-level thermal management performance while retaining the advantages of polymer materials including lower density, corrosion resistance, and design flexibility.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If thermally conductive polymers are used to conduct heat, then cost and weight are reduced, but thermal conductivity and heat resistance are insufficient

Engineering Contradiction:

Improvehousing weightVSAvoidthermal conductivity

Core Design Contradiction:

Weight of moving objectVSTemperature

Solution Approach 1:

The patent employs composite materials by combining a polymer matrix with thermally conductive filler particles. This composite approach enables the housing to achieve metal-level thermal management performance while retaining the advantages of polymer materials including lower density, corrosion resistance, and design flexibility.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by using a polymer matrix combined with thermally conductive fillers (such as aluminum oxide, aluminum nitride, boron nitride, or graphite) to achieve high thermal conductivity without the weight penalty of metals. The filler content is optimized to reach thermal conductivity of at least 3 W/m·K while maintaining polymer-based lightweight characteristics.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If conventional polymers are used for battery housing, then cost and ease of manufacture are improved, but mechanical strength and heat resistance are insufficient

Engineering Contradiction:

Improvemanufacturing easeVSAvoidmechanical strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent employs composite materials by combining a polymer matrix with thermally conductive filler particles. This composite approach enables the housing to achieve metal-level thermal management performance while retaining the advantages of polymer materials including lower density, corrosion resistance, and design flexibility.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the polymer composition by incorporating specific fillers and adjusting the polymer matrix properties to achieve both high thermal conductivity and adequate mechanical strength for automotive battery applications.

Inventive Principle:

Principle #35Parameter changes

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 polymer composition effectively manages heat in battery modules, providing high thermal conductivity and heat resistance while maintaining electrical insulativity and mechanical strength, thus enhancing the performance and safety of electric vehicle batteries.

Implementation Method 1

a thermally conductive filler distributed within the polymer matrix. The polymer composition exhibits an in-plane thermal conductivity of about 3 W/m-K or more

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a polymer matrix that includes a thermotropic liquid crystalline polymer and a thermally conductive filler distributed within the polymer matrix

Methodology Applied

Scientific EffectLiquid crystalline phase behavior: Liquid Crystals

Data Source

PatentUS20250140963A1Battery Module

Publication Date: 2025.05.01 TICONA LLC

AI summary

A battery module that comprises an electrochemical cell is provided. The battery module includes a polymer composition that comprises a polymer matrix that includes a thermotropic liquid crystalline polymer and a thermally conductive filler distributed within the polymer matrix. The polymer composition exhibits an in-plane thermal conductivity of about 3 W/m-K or more as determined in accordance with ASTM E1461-13 (2022) and a deflection temperature under load of about 230° C.) or more as determined in accordance with ISO 75:2013 at a load of 1.8 MPa.