Polyarylene Sulfide Composite for Thermal Shock-Resistant EV Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing polymer compositions used in electric vehicle components lack sufficient thermal shock resistance, leading to cracking when exposed to temperature changes.
Innovation Solution
A polymer composition comprising an impact modifier, mineral particles, and reinforcing fibers dispersed within a polyarylene sulfide matrix, which achieves a melt flow index of 500 to 1,000 grams per 10 minutes and a thermal shock resistance value of 800 or more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymer compositions are used in electric vehicle components, then manufacturing is simplified, but thermal shock resistance is insufficient leading to cracking under temperature changes
Solution Approach 1:
The patent applies composite materials by combining polyarylene sulfide base resin with specific additives including impact modifiers (1-20 parts by weight per 100 parts base resin), mineral particles (20-60 parts by weight per 100 parts base resin), and reinforcing fibers (10-50 parts by weight per 100 parts base resin). This composite structure provides both thermal shock resistance (≥800) and mechanical strength while avoiding cracking under temperature changes.
2Reliability
If polymer composition with high thermal shock resistance is developed, then cracking resistance improves, but achieving sufficient thermal shock resistance for EV applications remains difficult
Solution Approach 1:
The patent applies parameter changes by precisely controlling the melt flow index of the polyarylene sulfide base resin to be within 50-1000 g/10min (measured at 190°C, 2.16 kg load), and by optimizing the weight ratios of additives: impact modifiers (1-20 parts), mineral particles (20-60 parts), and reinforcing fibers (10-50 parts) per 100 parts base resin. These parameter optimizations achieve thermal shock resistance of ≥800 while preventing cracking.
Solution Approach 2:
The patent applies local quality by selecting specific types of additives with distinct functions: impact modifiers (such as polyethylene-propylene-diene copolymer) localized for crack prevention, mineral particles (such as talc or calcium carbonate) localized for thermal stability, and reinforcing fibers (such as glass or carbon fibers) localized for mechanical strength. Each additive type contributes specifically to different aspects of thermal shock resistance.
3Shape
If insert molding process is used to form complex parts, then part complexity is achieved, but cracking occurs due to stark differences in thermal expansion coefficients of different materials
Solution Approach 1:
The patent applies thermal expansion principles by incorporating mineral particles (such as talc or calcium carbonate) and reinforcing fibers that have thermal expansion coefficients matching or complementary to metal inserts. This reduces the thermal expansion mismatch between the polymer composition and metal inserts during insert molding, preventing cracking when parts are exposed to temperature changes while maintaining complex part geometries.
Data Source
AI summary
A polymer composition that comprises an impact modifier, mineral particles, and reinforcing fibers dispersed within a polymer matrix is provided. The polymer matrix contains a polyarylene sulfide and exhibits a melt flow index of from about 500 to about 1,000 grams per 10 minutes. The weight ratio of the reinforcing fibers to the mineral particles is about 2 or more. Further, the polymer composition exhibits a thermal shock resistance value of about 800 or more.