Urethane Resin for Battery Modules

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Solution Overview

Problem

Existing battery modules and packs face challenges with increased manufacturing costs, volume, and weight due to the need for fastening parts and cooling equipment, which also compromise their power and durability, especially when exposed to external shocks like vibration.

Innovation Solution

A two-component urethane-based resin composition is used for fixing battery cells in a module case, providing excellent processability, heat dissipation, adhesive force, and adhesion reliability through a room temperature curing process, incorporating a polyol resin and isocyanate with specific glass transition temperature ranges and fillers for enhanced impact resistance and thermal conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fastening parts and cooling equipment are added to battery modules, then structural stability and cooling function are improved, but manufacturing cost, volume, and weight increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidbattery module weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent combines multiple functions (fastening, cooling, cushioning, insulation) into a single resin layer that fills the void space between battery cells. This eliminates the need for separate fastening parts and cooling equipment, reducing weight while maintaining structural stability and cooling efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The resin layer serves multiple purposes simultaneously: it acts as a fastening medium to secure battery cells, provides thermal conduction for cooling, offers cushioning against external shocks, and ensures electrical insulation. This multi-functionality reduces the number of components needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If fastening parts and cooling equipment are added to battery modules, then structural stability and cooling function are improved, but manufacturing cost, volume, and weight increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidbattery module complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If fastening parts and cooling equipment are added to battery modules, then structural stability and cooling function are improved, but manufacturing cost, volume, and weight increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidbattery module weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of manufacture

If battery cells are fixed with traditional methods, then manufacturing process is simple, but heat dissipation performance is insufficient

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidheat dissipation performance

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The patent changes the thermal parameters of the fixing medium by using a resin composition with high thermal conductivity (achieved through filler content of 30-80 wt%). This allows the resin layer to not only secure battery cells but also efficiently conduct heat away, improving heat dissipation without complicating the manufacturing process.

Inventive Principle:

Principle #35Parameter changes

5Temperature

If filler content is increased to improve thermal conductivity, then heat dissipation performance is improved, but viscosity of resin composition increases

Engineering Contradiction:

Improvethermal conductivityVSAvoidinjection processability

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent optimizes the resin composition parameters by selecting specific polyol types (ester-based with low crystallizability) and controlling molecular weight and hydroxyl value. This allows achieving high thermal conductivity through fillers while maintaining injection processability by preventing crystallization during the injection process.

Inventive Principle:

Principle #35Parameter 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 solution results in a battery module with improved heat dissipation, durability, and reduced weight, enabling higher power-to-volume ratios while maintaining reliability and safety against vibrations and impacts.

Implementation Method 1

a main material comprising a polyol and the like and a curing agent comprising an isocyanate and the like may react at room temperature and be cured

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

excellent processability as well as heat dissipation

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

excellent adhesion reliability... improved durability... reduced weight, enabling higher power-to-volume ratios while maintaining reliability and safety against vibrations and impacts

Methodology Applied

Scientific EffectViscoelasticity: Viscoelasticity

Data Source

PatentUS11634533B2Resin composition

Publication Date: 2023.04.25 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, it is possible to provide a battery module and a battery pack which have improved heat dissipation properties, adhesive force, adhesion reliability and processability as well as excellent power to volume.