Polyurethane Thermal Interface Material With Anti-Sliding ATH Filler
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Solution Overview
Problem
Current thermal interface materials (TIM) for battery-powered vehicles, especially those using aluminum trihydroxide (ATH) as fillers, face issues with sliding when placed vertically under climate conditions, which affects their thermal management efficiency.
Innovation Solution
A thermal interface material composition comprising a non-reactive polyurethane prepolymer, 70-95 wt% aluminum trihydroxide, 0.15-1.5 wt% silane terminated urethane prepolymer, and 1-20 wt% plasticizer, with the silane terminated urethane prepolymer being key in preventing sliding and improving viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If aluminum trihydroxide (ATH) is used as filler to achieve high thermal conductivity and low viscosity, then thermal conductivity is improved, but the material tends to slide when placed vertically
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating silane terminated urethane prepolymers (0.1-5 wt%) into the polyurethane matrix. This chemical modification alters the material's rheological properties, specifically improving its anti-sag characteristics and vertical stability while preserving the thermal conductivity benefits of high ATH content (70-95 wt%).
Solution Approach 2:
The patent creates a composite material system combining polyurethane prepolymer, aluminum trihydroxide filler, and silane terminated urethane prepolymer. This composite approach allows the silane component to provide structural reinforcement and improved adhesion, preventing sliding while the ATH filler maintains high thermal conductivity.
2Temperature
If high loading of ATH is used to achieve high thermal conductivity, then thermal management performance is improved, but viscosity control becomes challenging
Solution Approach 1:
The patent utilizes silane terminated urethane prepolymers to modify the viscosity parameters of the TIM composition. This allows achieving optimal flow characteristics and spreadability even with high ATH loading (70-95 wt%), enabling proper application while maintaining high thermal conductivity performance.
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 effectively prevents sliding and maintains thermal conductivity, ensuring reliable heat management in battery-powered vehicles by incorporating silane terminated urethane prepolymers, which enhances the material's stability and usability.
Implementation Method 1
0.15-1.5 wt% of at least one silane terminated urethane prepolymer
Implementation Method 2
a non-reactive polyurethane prepolymer... 70-95 wt% of aluminum trihydroxide
Implementation Method 3
thermal interface materials (TIM)... connected to the cooling unit via the thermal interface material composition
Data Source
AI summary
Disclosed herein are thermal interface materials (TIM) composition comprising: a) a non-reactive polyurethane prepolymer; b) about 70-95 wt% of aluminum trihydroxide (ATH); c) about 0.15-1.5 wt% of at least one silane terminated urethane prepolymer; and d) about 1-20 wt% of at least one plasticizer, with the total weight of the thermal interface material totaling to 100 wt%.