Two-Part Thermal Interface Material for Low-Viscosity Gap Filling
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Solution Overview
Problem
Current thermal interface materials for electric vehicles face challenges such as insufficient thermal conductivity, difficulty in filling gaps, poor shelf stability, high costs, and the use of abrasive fillers, which hinder effective thermal management in battery systems.
Innovation Solution
A two-part thermal interface material composition comprising a prepolymer with carbamate groups and a polyamine compound, along with conductive fillers like aluminum hydroxide, that reacts at room temperature to provide high thermal conductivity and flowability, while avoiding abrasive fillers and maintaining low viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high filler content is used to increase thermal conductivity, then thermal conductivity is improved, but viscosity increases making the material difficult to flow and fill gaps
Solution Approach 1:
The composition is divided into two separate parts that are mixed immediately before application. Part A contains the carbamate-containing compound and Part B contains the carbamate-reactive compound with conductive filler. This segmentation allows each part to be optimized independently - Part B can have high filler content while the uncured two-part system maintains low viscosity for easy application.
Solution Approach 2:
The patent changes the chemical state of the matrix phase from cured to uncured by using a two-part reactive composition. The uncured state provides low viscosity and flowability, while the high filler content (50 wt% or more) provides high thermal conductivity. After application, the reaction between Part A and Part B cures the composition, locking in both the high thermal conductivity and gap-filling properties.
2Stability of the object's composition
If reactive two-part composition is used to improve shelf stability, then shelf stability is improved, but the components must react at appropriate conditions which complicates the composition
Solution Approach 1:
The patent utilizes changes in reaction parameters (temperature, catalyst presence) to control the reactivity of the two-part composition. The carbamate-containing compound (Part A) and carbamate-reactive compound (Part B) remain stable separately during storage but react when mixed and applied. The reaction can be controlled to proceed at room temperature or with mild heating, providing shelf stability during storage while enabling curing after application.
3Reliability
If conventional thermal interface materials are used, then manufacturing is simpler, but thermal conductivity is insufficient for effective battery thermal management
Solution Approach 1:
The patent creates a composite material system combining organic matrix phases (carbamate-containing compound and carbamate-reactive compound) with inorganic conductive fillers (such as aluminum oxide, aluminum hydroxide, boron nitride). This composite structure achieves high thermal conductivity (50 wt% or more filler content) while maintaining processability through the two-part reactive composition approach. The composite nature allows optimization of both thermal performance and manufacturing characteristics.
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 solution achieves high thermal conductivity, improved gap filling capabilities, and enhanced shelf stability, reducing material costs and preventing damage to processing equipment, thus effectively managing thermal energy transfer in electric vehicle batteries.
Implementation Method 1
a first part comprising at least a prepolymer including two or more carbamate groups; and a second part comprising at least one or more polyamine compounds capable of a reaction with the prepolymer
Implementation Method 2
one or more thermally conductive fillers dispersed in the matrix phase
Data Source
AI summary
A new composition for thermal interface materials that provide improved thermal conductivity without requiring filler materials that are expensive or abrasive.