Polymeric Catalyst Gap Filler for Open Time and Fast Cure
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Solution Overview
Problem
Existing aerospace sealants face challenges in achieving a desirable balance between long application time and short curing time, while electric vehicle thermal gap fillers suffer from contamination issues and thermal conductivity problems due to non-functional polymers and gas bubbles.
Innovation Solution
A composition comprising a polythiol, a polyepoxide, a polymer with tertiary amine and hydroxyl groups, and a conductive filler, which allows for a slower initiation phase, reduced surface blooming, and high filler loading, resulting in a thermally conductive gap filler with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional amine catalysts are used for polythiol-polyepoxide crosslinking, then curing speed is improved, but open time becomes too short
Solution Approach 1:
The patent changes the chemical structure parameters of the catalyst from conventional small-molecule amines to polymers containing tertiary amine groups and hydroxyl groups. This structural modification alters the catalyst's reactivity parameters, providing a slower initiation phase that extends open time while maintaining acceptable curing speed through the synergistic action of multiple functional groups.
Solution Approach 2:
The invention uses composite catalyst systems combining polymers with both tertiary amine groups and hydroxyl groups. This composite structure allows the material to exhibit dual functionality: the tertiary amine provides catalytic activity for crosslinking while the hydroxyl groups modulate the reaction kinetics, achieving a balance between open time and curing speed that neither functional group could provide alone.
2Temperature
If high loading levels of conductive fillers are added to achieve thermal conductivity, then thermal performance is improved, but viscosity increases and material properties deteriorate
Solution Approach 1:
The patent modifies the chemical composition parameters of the base resin system by using polythiol-polyepoxide crosslinked networks. This changes the rheological parameters of the composition, allowing it to accommodate high filler loadings (exceeding 60 wt%) while maintaining workable viscosity and achieving excellent thermal conductivity and elongation properties after curing.
3Productivity
If conventional amine catalysts are used, then catalytic activity is improved, but surface blooming occurs
Solution Approach 1:
The invention extracts the problematic small-molecule amine catalyst and replaces it with polymeric catalyst systems. This removal of the blooming-prone component eliminates the surface blooming defect while retaining catalytic functionality through the polymer-embedded tertiary amine and hydroxyl groups that remain trapped within the bulk matrix.
4Strength
If silicone or polyurethane elastomers are used for thermal gap fillers, then elastomeric properties are improved, but contamination and gas bubbles occur
Solution Approach 1:
The patent replaces conventional silicone and polyurethane elastomers with a polythiol-polyepoxide crosslinked system. This substitution eliminates the production-related contaminants (silicone oil residuals, volatile residuals) and eliminates gas bubble formation associated with isocyanate curing, while maintaining elastomeric properties through the crosslinked network structure.
Solution Approach 2:
The invention creates a composite chemical system combining polythiol, polyepoxide, and conductive fillers within a crosslinked polymer network. This composite approach achieves elastomeric properties through chemical crosslinking rather than relying on conventional elastomer matrices, simultaneously avoiding the contamination and gas bubble issues inherent in those materials.
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 a balance of long open time and short curing time, maintains viscosity, and supports high elongation, while minimizing contamination and gas bubbles, enhancing thermal conductivity and adhesion.
Implementation Method 1
a polymer comprising a tertiary amine group and a hydroxyl group, wherein the polymer comprising the tertiary amine group and the hydroxyl group acts as a catalyst for the polythiol and polyepoxide
Implementation Method 2
transfer heat away from an electronic module and direct it toward a cooling plate
Data Source
AI summary
A composition includes a polythiol having more than one thiol group, a polyepoxide having more than one epoxide group, a polymer comprising a tertiary amine group and a hydroxyl group, and conductive filler. A polymer network, which can be prepared from the composition, a method for making the polymer network, a method of making a battery module, and a battery module including the composition are also disclosed.