Curable Thermal Interface Composition for EV Battery Heat Transfer

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Solution Overview

Problem

Existing thermal interface materials used in small electronic devices are not suitable for larger heat sources like electric vehicle batteries, requiring thermal interface materials with high thermal conductivity, flexibility, and customizable dispense rates that are also silicone-free.

Innovation Solution

A two-part thermally conductive curable composition comprising a catalyst and a reactive polymer, with a ceramic filler mixture and low volatile organic liquid, which cures at room temperature to form a solid thermal interface material with high thermal conductivity and customizable dispense rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If thermal interface materials with high thermal conductivity are used, then heat transfer efficiency is improved, but the materials become less flexible and harder to dispense

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidflexibility and dispenseability

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The patent modifies the chemical composition parameters of the thermal interface material by incorporating specific silicone polymers and ceramic fillers in controlled ratios. This allows the material to maintain high thermal conductivity while preserving flexibility and proper dispense characteristics for large-scale applications.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite thermal interface material combining silicone polymer base components with ceramic filler particles. This composite structure enables the material to simultaneously achieve high thermal conductivity from the ceramic phase while maintaining flexibility and processability from the silicone polymer phase.

Inventive Principle:

Principle #40Composite materials

2Reliability

If thermal interface materials are formulated for small electronic devices, then they provide adequate thermal management, but they are not suitable for larger heat sources like electric vehicle batteries

Engineering Contradiction:

Improvethermal management effectivenessVSAvoidscalability to larger heat sources

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent formulates a universal thermal interface material composition that can be adapted for both small electronic devices and large electric vehicle battery packs. The material's rheological properties, thermal conductivity, and curing characteristics are optimized to provide reliable thermal management across different scale applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention creates a thermally conductive curable composition that transitions from a dispensable liquid or paste state to a solid cured state. This dynamic property change allows the material to be easily dispensed and applied to large battery surfaces, then固化 to provide stable, long-term thermal management performance.

Inventive Principle:

Principle #15Dynamics

3Temperature

If silicone-containing thermal interface materials are used, then thermal conductivity is improved, but safety concerns arise due to potential combustion

Engineering Contradiction:

Improvethermal conductivityVSAvoidcombustion risk

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent carefully controls the chemical composition parameters, selecting silicone polymers and ceramic fillers with appropriate fire resistance properties. The formulation achieves the required thermal conductivity while incorporating materials that meet safety standards and reduce combustion risk in 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 composition provides effective thermal management for electric vehicle batteries, maintaining optimal temperature and preventing overheating, while ensuring safety and longevity.

Implementation Method 1

a second part comprising a silyl modified reactive polymer... wherein the composition cures at room temperature to form a solid thermal interface material

Methodology Applied

Scientific EffectCondensation reaction:

Implementation Method 2

thermal interface materials are used provide an intimate contact between the heat source and the heat-sinking structure... high thermal conductivity

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12441881B2Thermal interface materials

Publication Date: 2025.10.14 HENKEL KGAA

AI summary

A thermally conductive curable composition includes a first part and a second part, wherein the first part comprises a catalyst, a ceramic filler mixture, a low volatile organic liquid, and water, and the second part comprises a silyl modified reactive polymer, a low volatile organic liquid, and the ceramic filler mixture, and the low volatile organic liquid is present in the composition in an amount greater than about 50 wt. % based on the total weight of the silyl modified reactive polymer.