Two-Component Polyurethane Gap Filler for Battery Thermal Management
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Solution Overview
Problem
Existing thermally conductive silicone gap fillers fail to provide sufficient adhesion to metallic substances in secondary cell modules and packs, and their preservation stability is degraded due to rapid reaction with moisture, requiring a solution that can maintain stability at room temperature for extended periods.
Innovation Solution
A two-component thermally conductive polyurethane composition comprising a primary agent with polyols and a curing agent containing a moisture scavenger and curing retardant, which includes thermally conductive and flame-retardant ceramics, dispersing agents, and thixotropy additives, to enhance adhesion and preservation stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If silicone compositions are used as thermally conductive gap fillers, then thermal conductivity and thermal resistance are improved, but adhesion to metallic substances is insufficient
Solution Approach 1:
The patent uses a composite material system combining polyurethane base polymer with ceramic fillers (alumina, silica) and specific additives. This composite structure provides both thermal conductivity through the ceramic particles and adhesion through the polyurethane matrix, resolving the contradiction between thermal performance and bonding strength to metallic surfaces.
Solution Approach 2:
The patent modifies the chemical composition parameters of the gap filler by incorporating specific ceramic fillers (alumina with 20-80 wt%, silica with 5-50 wt%) and controlling the molecular weight and hydroxyl value of the polyol (500-5000 cP, 50-500 mg KOH/g). These parameter adjustments optimize both thermal conductivity and adhesion properties simultaneously.
2Strength
If polyol reacts with isocyanate to form polyurethane, then adhesion to metallic surfaces is improved, but preservation stability is degraded due to rapid reaction with moisture
Solution Approach 1:
The patent introduces a moisture scavenger (oxazolidine derivative) as an intermediary substance that preferentially reacts with moisture before the isocyanate can react with moisture. This mediator protects the isocyanate group from premature reaction while maintaining the desired adhesion properties, thereby improving preservation stability.
Solution Approach 2:
The patent extracts and removes moisture from the system using a moisture scavenger (oxazolidine derivative) that reacts with and eliminates water molecules. This extraction of the harmful moisture component prevents unwanted side reactions and maintains composition stability during storage.
3Ease of operation
If curing agent composition is stored at room temperature, then ease of operation is improved, but preservation stability is degraded due to rapid reaction with moisture
Solution Approach 1:
The moisture scavenger (oxazolidine derivative) acts as a protective intermediary that intercepts moisture molecules before they can react with the isocyanate groups in the curing agent. This allows the curing agent to be stored at convenient room temperatures without undergoing premature reaction, thus maintaining both ease of operation and preservation stability.
Solution Approach 2:
The patent converts the potentially harmful effect of moisture into a beneficial process by using the moisture scavenger to react with and remove moisture. This transforms the moisture problem into an advantage, as the scavenger effectively protects the curing agent from moisture-related degradation while allowing convenient room temperature storage.
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 long-term preservation at room temperature for 180 days or more, providing effective thermal conductivity and adhesion to metallic surfaces, thereby improving the performance and safety of secondary cell modules and packs.
Implementation Method 1
a moisture scavenger... which reacts with moisture
Implementation Method 2
thermally conductive gap filler... thermal conductivity
Implementation Method 3
a polyol... reacts with an isocyanate group
Data Source
AI summary
The present invention relates to a two-component thermally conductive polyurethane gap filler composition and, more particularly, provides a two-component thermally conductive polyurethane gap filler composition comprising: a primary composition comprising a catalyst and two or more mixtures selected from a polyol having one hydroxyl group, a polyol having two hydroxyl groups, and a polyol having 3 to 64 hydroxyl groups; and a curing agent composition comprising a moisture scavenger, a curing retardant, and at least one selected from a monomer having 2 or less isocyanate groups at a terminal and a polyurethane precursor obtained by reacting a monomer having 2 or less isocyanate groups at a terminal and a polyol.