Unsaturated Polyester Resin Composition for Stable EV Battery Casings
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Solution Overview
Problem
Molded articles made from existing unsaturated polyester resin compositions exhibit poor dimensional stability when combined with light metals due to differences in linear expansion coefficients, and they lack low shrinkage, flame retardancy, and electromagnetic shielding properties required for advanced applications.
Innovation Solution
An unsaturated polyester resin composition is developed, incorporating a polymerization product of a polybasic acid with an ethylenically unsaturated double bond, polyvinyl acetate as a low shrinkage agent, aluminum hydroxide for flame retardancy, and an electrically conductive filler to enhance dimensional stability and electromagnetic shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional unsaturated polyester resin composition is used, then manufacturing simplicity is maintained, but dimensional stability deteriorates when combined with light metals due to linear expansion coefficient differences
Solution Approach 1:
The patent uses a composite resin composition containing unsaturated polyester resin, polyvinyl acetate, aluminum hydroxide, and electrically conductive filler. This multi-component composite system achieves dimensional stability matching light metals while providing additional functions like flame retardancy and electromagnetic shielding, resolving the contradiction between stability improvement and composition complexity.
Solution Approach 2:
The patent adjusts the linear expansion coefficient of the resin composition by selecting specific ratios of polybasic acid (80 mol% or more with ethylenically unsaturated double bond) and adding aluminum hydroxide, thereby matching the linear expansion coefficient of light metals. This parameter adjustment resolves the dimensional stability issue without requiring overly complex composition design.
2Manufacturing precision
If conventional resin composition is used, then formulation simplicity is maintained, but low shrinkage property deteriorates
Solution Approach 1:
The patent introduces polyvinyl acetate as a low shrinkage agent that acts as an intermediary component between the unsaturated polyester resin and the final cured product. This additive suppresses shrinkage during curing and cooling processes, achieving manufacturing precision without fundamentally changing the base resin system.
3Object-affected harmful factors
If conventional resin composition is used, then formulation simplicity is maintained, but flame retardancy deteriorates
Solution Approach 1:
The patent converts the typically harmful effect of combustion into a beneficial flame retardant mechanism by incorporating aluminum hydroxide. When exposed to fire, aluminum hydroxide decomposes endothermically, absorbing heat and releasing water vapor to suppress combustion, thereby converting thermal energy that would cause damage into a protective flame retardant action.
4Object-affected harmful factors
If conventional resin composition is used, then formulation simplicity is maintained, but electromagnetic shielding properties deteriorate
Solution Approach 1:
The patent creates a composite material system that incorporates electrically conductive filler (such as carbon fiber or metal particles) into the unsaturated polyester resin matrix. This composite structure provides electromagnetic shielding by reflecting or absorbing electromagnetic waves, while the polyvinyl acetate and aluminum hydroxide components maintain other required properties like low shrinkage and flame retardancy.
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 excellent low shrinkage, flame retardancy, and electromagnetic shielding properties, while maintaining dimensional stability even when used in combination with light metals, making it suitable for applications like battery pack casings for electric vehicles.
Implementation Method 1
aluminum hydroxide... for flame retardancy
Implementation Method 2
electrically conductive filler... electromagnetic shielding properties
Implementation Method 3
polyvinyl acetate... as a low shrinkage agent
Data Source
AI summary
An unsaturated polyester resin composition includes an unsaturated polyester, a polymerizable monomer, a low shrinkage agent, aluminum hydroxide, and an electrically conductive filler. The unsaturated polyester is a polymerization product of a polybasic acid including a polybasic acid having an ethylenically unsaturated double bond at a predetermined ratio and a polyhydric alcohol. A polyvinyl acetate as the low shrinkage agent is included at a predetermined ratio with respect to the total amount of the unsaturated polyester, the polymerizable monomer, and the low shrinkage agent. The aluminum hydroxide is included at a predetermined ratio with respect to the total amount of the unsaturated polyester, the polymerizable monomer, and the low shrinkage agent.