Thermally Conductive Coating Composition for Battery Thermal Management
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Solution Overview
Problem
Existing coating compositions lack sufficient thermal conductivity and mechanical strength, particularly in applications requiring both thermal management and structural integrity, such as in battery cells and assemblies.
Innovation Solution
A two-component composition comprising an isocyanate functional prepolymer formed from a polyisocyanate and a polyol with more than two hydroxyl functional groups, combined with a thermally conductive filler, to achieve enhanced thermal conductivity and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional coating compositions are used, then ease of manufacture is maintained, but thermal conductivity is insufficient
Solution Approach 1:
The patent employs composite materials by combining thermally conductive fillers (such as aluminum oxide, aluminum nitride, or boron nitride) with polyol components to create a coating composition that achieves enhanced thermal conductivity (at least 0.5 W/m-K) while maintaining manufacturability. The composite structure allows heat conduction pathways to be established within the coating matrix without fundamentally altering the manufacturing process.
2Temperature
If thermally conductive fillers are added to enhance thermal conductivity, then thermal management capability is improved, but mechanical strength may be compromised
Solution Approach 1:
The patent optimizes the parameters of the coating composition by controlling the weight percentage of thermally conductive filler (typically 1-50 wt%), the molecular weight and functionality of the polyol, and the curing conditions. These parameter adjustments enable the coating to achieve a balance where thermal conductivity reaches at least 0.5 W/m-K while maintaining adequate mechanical strength for structural applications.
Solution Approach 2:
The coating forms a composite structure where thermally conductive filler particles are distributed within the polyol matrix, creating pathways for heat conduction while the polyol binder maintains the structural integrity and mechanical strength of the coating. This composite approach allows simultaneous achievement of thermal management and structural properties.
3Temperature
If high filler content is used to maximize thermal conductivity, then thermal management performance is improved, but elongation and flexibility deteriorate
Solution Approach 1:
The patent carefully controls the filler content within optimal ranges (typically not exceeding 50 wt% of total composition) and adjusts polyol parameters such as hydroxyl value and molecular weight to maintain flexibility. This parameter optimization ensures the coating achieves sufficient thermal conductivity (≥0.5 W/m-K) while retaining elongation capabilities between 1% to 300% for accommodating thermal expansion and maintaining adhesion.
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 composition achieves thermal conductivity of at least 0.5 W/m-K, lap shear strength of at least 0.1 MPa, tensile strength of at least 0.01 MPa, and elongation of 1% to 300%, making it suitable for applications requiring both thermal management and structural integrity.
Implementation Method 1
a thermal conductivity of at least 0.5 W/m-K measured using a Modified Transient Plane Source method conformed to ASTM D7984
Data Source
AI summary
Disclosed are compositions comprising a first component, a second component, and thermally conductive filler. The first component comprises an isocyanate functional prepolymer formed as a reaction product of reactants comprising a first polyisocyanate and a polyester polyol or a polyether polyol, the polyol comprising more than two hydroxyl functional groups. The second component comprises a polyol. Also disclosed are methods of coating a substrate and substrates comprising a coating formed on a surface from a composition disclosed herein. Also disclosed are batteries comprising a battery cell and any of the compositions disclosed herein in an at least partially cured state. Also disclosed are uses of the compositions disclosed herein.