Resin Composition for Battery Modules with Dynamic Viscosity Control

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Solution Overview

Problem

The existing adhesive compositions for battery modules have issues with injection processability, leading to potential contamination and peeling between components due to rapid curing or insufficient curing, which affects the integrity and reliability of the battery module.

Innovation Solution

A curable resin composition with specific viscosity characteristics is developed, allowing for controlled curing rates to ensure proper processability and adhesion, featuring a two-component urethane-based system with a polyol and isocyanate reaction, assisted by a catalyst like dibutyltin dilaurate, and incorporating fillers for enhanced thermal conductivity and insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the curing rate of the resin composition is increased to improve adhesion speed, then the adhesive sets faster, but the viscosity increases rapidly making injection difficult

Engineering Contradiction:

Improveadhesion speedVSAvoidinjection processability

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The resin composition is designed with dynamic viscosity characteristics that change over time: initially low viscosity for easy injection, then gradually increasing as curing progresses. This time-dependent viscosity adjustment allows the adhesive to be injected smoothly before the curing reaction significantly increases viscosity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent adjusts the chemical composition parameters including the types and ratios of polyols, isocyanates, and catalysts to control the curing kinetics. By optimizing these parameters, the adhesive achieves a balanced curing rate that provides sufficient injection time while maintaining fast adhesion performance.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the curing rate is too fast, then adhesion is achieved quickly, but the adhesive may leak or components may be contaminated during handling

Engineering Contradiction:

Improveadhesion speedVSAvoidcontamination prevention

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The adhesive formulation includes ingredients that promote rapid initial curing at the bonding interface while maintaining lower overall viscosity for a controlled period. This preliminary action at the contact surface ensures strong adhesion before the bulk material cures completely, preventing leakage and contamination during subsequent handling operations.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If the curing rate is too slow, then injection and handling are easier, but the adhesive remains liquid and may leak or cause contamination

Engineering Contradiction:

Improveinjection processabilityVSAvoidcontamination prevention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The resin composition exhibits dynamic rheological properties where viscosity increases progressively during the curing process. This dynamic behavior allows the adhesive to remain injectable during the process while automatically gaining sufficient viscosity to prevent leakage once injection is complete, ensuring both ease of manufacture and reliability.

Inventive Principle:

Principle #15Dynamics

4Productivity

If a fast-curing adhesive is used to improve productivity, then adhesion is achieved quickly, but the interface between components may lift due to insufficient curing

Engineering Contradiction:

Improveadhesion speedVSAvoidinterface bonding strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The curing system is designed to provide continuous and progressive curing action rather than abrupt completion. The catalyst and reactant formulation ensures that the curing reaction continues at an appropriate rate after injection, allowing the adhesive to maintain bonding strength and prevent interface lifting while still achieving fast initial adhesion.

Inventive Principle:

Principle #20Continuity of useful action

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 resin composition ensures excellent injection processability, prevents contamination, and provides strong adhesion and insulation properties after curing, maintaining the structural integrity of the battery module and ensuring reliable performance.

Implementation Method 1

a two-component urethane-based system with a polyol and isocyanate reaction

Methodology Applied

Scientific EffectUrethane reaction: Chemical Bonding

Implementation Method 2

assisted by a catalyst like dibutyltin dilaurate

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

incorporating fillers for enhanced thermal conductivity

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

provides excellent insulating property after being injected into a battery module and cured

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Data Source

PatentUS11603427B2Resin composition

Publication Date: 2023.03.14 LG CHEM LTD

AI summary

The present application relates to a composition, a battery module and a battery pack. According to one example of the present application, the related manufacturing process can be improved and a battery module having excellent insulation can be provided.