Thermally Conductive Polymer Composition for EV Heat Dissipation
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Solution Overview
Problem
Conventional polymeric materials used in electric vehicles lack sufficient thermal conductivity, necessitating the use of heat sinks that occupy valuable space, which is undesirable.
Innovation Solution
A polymer composition comprising a polyarylene sulfide matrix with dispersed mineral particles, achieving high thermal conductivity without the need for heat sinks, allowing for effective heat dissipation from electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional polymeric materials are used, then ease of manufacture and mechanical properties are maintained, but thermal conductivity is insufficient requiring additional heat sinks
Solution Approach 1:
The patent creates a composite polymeric material by dispersing thermally conductive particles (such as metal oxides, ceramic particles, or carbon-based materials) within a polymer matrix. This composite structure combines the mechanical advantages of polymers with the thermal conductivity of the dispersed particles, enabling the material to dissipate heat effectively without requiring separate heat sink components.
Solution Approach 2:
The patent modifies the thermal conductivity parameter of the polymeric material by controlling the type, amount, size, and distribution of thermally conductive particles within the matrix. By adjusting these parameters, the material achieves sufficient thermal conductivity to eliminate the need for additional heat sinks while maintaining appropriate mechanical properties.
2Temperature
If heat sinks are attached to components, then thermal conductivity is improved, but device complexity and space occupation increase
Solution Approach 1:
The patent merges the structural component function with the heat dissipation function by incorporating thermally conductive particles directly into the polymeric material that forms the component housing or structure. This integration eliminates the need for separate heat sink attachments, reducing structural complexity and space requirements while maintaining effective heat dissipation.
3Temperature
If thermally conductive particles are added to polymer matrix, then thermal conductivity is improved, but manufacturing precision and material homogeneity may be affected
Solution Approach 1:
The patent optimizes manufacturing parameters such as particle size distribution, particle concentration, mixing temperature, and processing time to achieve uniform particle dispersion within the polymer matrix. By carefully controlling these parameters, the patent maintains material homogeneity and manufacturing precision while achieving the desired thermal conductivity enhancement.
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 exhibits enhanced thermal conductivity, enabling efficient heat transfer and reduced temperature in electric vehicle components, while maintaining mechanical strength and flexibility, and is suitable for use in thin part thicknesses.
Implementation Method 1
The polymer composition exhibits an in-plane thermal conductivity of about 2 W/m-K or more
Data Source
AI summary
A polymer composition comprising 100 parts by weight of a polymer matrix that includes a polyarylene sulfide and from about 40 to about 200 parts by weight of a plurality of mineral particles dispersed within the polymer matrix is provided. The polymer composition exhibits an in-plane thermal conductivity of about 2.5 W/m-K or more as determined in accordance with ASTM E1461-13(2022).