Silane-Terminated Thermal Gap Filler for Battery Breathing
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Solution Overview
Problem
Existing silane-functional polymer compositions exhibit poor thermal conductivity and inadequate mechanical properties, failing to efficiently manage heat dissipation and accommodate battery breathing-induced deformations in electronic equipment.
Innovation Solution
A curable composition comprising organic polymers with reactive silane groups, thermally conductive fillers, plasticizers, and catalysts, which includes a combination of aluminium oxide and aluminium hydroxide fillers, achieves high thermal conductivity and mechanical stability, accommodating battery breathing deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditionally used silane-functional polymer compositions are employed, then the composition provides basic adhesive and sealant properties, but the thermal conductivity is poor and acts as thermal insulator
Solution Approach 1:
The patent employs composite materials by incorporating thermally conductive fillers (such as aluminum oxide, aluminum nitride, boron nitride, or zinc oxide) into the silane-functional polymer matrix. This creates a composite composition that combines the adhesive properties of the polymer with the high thermal conductivity of the fillers, effectively resolving the contradiction between providing basic sealant properties and achieving high thermal conductivity for heat dissipation.
2Adaptability or versatility
If the composition needs to accommodate battery breathing deformations, then the composition requires high elasticity and deformation capacity, but this may compromise mechanical strength and structural integrity
Solution Approach 1:
The patent utilizes parameter changes by carefully adjusting the polymer matrix composition, crosslinking density, and filler content to achieve an optimal balance between elasticity and strength. The silane-functional polymer provides a flexible base that can deform with battery breathing, while the controlled crosslinking and filler reinforcement maintain sufficient mechanical strength, allowing the composition to adapt to dimensional variations without compromising structural integrity.
3Temperature
If high filler content is used to improve thermal conductivity, then the thermal conductivity increases, but the composition becomes more rigid and less able to accommodate deformations
Solution Approach 1:
The patent applies local quality by strategically selecting and distributing different types of fillers with varying thermal conductivities and particle sizes within the polymer matrix. This localized optimization allows regions with higher filler concentration to provide thermal conductivity, while the polymer-rich regions maintain flexibility and deformation capacity, effectively resolving the contradiction between thermal performance and dimensional stability.
4Force
If the composition provides adequate mechanical load transfer, then the structural reinforcement is sufficient, but the composition may become too rigid to handle battery expansions and contractions
Solution Approach 1:
The patent implements dynamics by creating a composition that transitions from a rigid state to a more flexible, adaptive state in response to mechanical stress and thermal cycling. The silane-functional polymer matrix with controlled crosslinking provides initial mechanical strength for load transfer, while the flexibility allows the composition to dynamically adapt to battery breathing deformations, maintaining both structural reinforcement and responsiveness to dimensional changes.
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 excellent thermal conductivity (≥1.5 W/mK) and mechanical stability, effectively managing heat dissipation and structural integrity in electronic devices, particularly in automotive applications.
Implementation Method 1
which hydrolyze under the influence of moisture, condense with one another as silanol groups and thus form a covalently bonded network
Implementation Method 2
condense with one another as silanol groups and thus form a covalently bonded network
Implementation Method 3
a particular requirement for these compositions is high thermal conductivity because batteries and electronics generate significant amounts of heat while operating that must be dissipated efficiently
Data Source
AI summary
The invention relates to a curable silane-terminated polymer composition with high thermal conductivity and enhanced dimensional stability to accommodate for battery breathing, comprising at least one organic polymer P containing reactive silane groups, wherein the reactive silane groups correspond to dialkoxy(alkyl) silanes, and at least 70 wt.-% of thermally conductive filler F and at least one plasticizer PL and at least one catalyst C. The inventive curable composition is especially suitable as an adhesive, sealant or gap filler for batteries and other electronic equipment, especially in the automotive industry.