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Among various thermal conductive adhesives, the important ones here refer to epoxy resin thermal conductive adhesive, organic silicon thermal conductive adhesive, and polyurethane thermal conductive adhesive. The best comprehensive performance is undoubtedly thermal conductive silicone, which was originally developed to meet the constantly upgrading power dissipation needs of electronic circuits. Devices with high heating power may cause fatal damage if they cannot dissipate heat evenly and generate high hotspots.

Silicone properties

Organic silica gel is soft and has two forms: solid rubber and silicon gel, which can eliminate most of the mechanical stress and provide shock absorption protection. Stable physical and chemical properties, with good resistance to high and low temperatures, can work for a long time in the range of -50~200 ℃. Excellent weather resistance, can still provide good protection for outdoor use for more than 20 years, and is not prone to yellowing. It has excellent electrical performance and insulation ability, effectively improving the insulation between internal components and circuits after sealing, and improving the stability of electronic components. With the ability to repair, sealed components can be quickly and conveniently removed for repair and replacement. Silicone sheets can evenly export heat from the device, preventing harm caused by excessive heat concentration.

The use of organic silicon materials in heat dissipation is important in making the contact between heating devices and heat dissipation materials closer. We all know that heat dissipation materials are generally made of high thermal conductivity metal materials such as aluminum and copper, and heating devices are usually solid. The contact between solids has many gaps on the surface, which reduces the thermal conductivity between them. If a soft and thermally conductive interface material is applied to their contact interface, this problem can be solved. Organic silicon is a material that precisely possesses these two characteristics.

Typical products and parameters of thermal conductive silicone

Specifically in the power lithium battery system, the application forms of silicone include several forms, including sealing adhesive, silicone sheet, silicone grease, and adhesive. The parameters of several typical silicone products are listed below, and it should be emphasized that they are only individual typical product parameters. However, no particularly suitable images of the corresponding application for power lithium batteries were found, and electronic product images were used to assist in understanding.

1) Thermal conductive sealing silicone

Comparing the three types of sealing adhesive, it can be found that silicone has the lowest density that can be achieved. Low density, detachable, is an important characteristic of thermal conductive silicone that is more suitable for applications in power lithium battery systems.

Color: White, black viscous liquid; Application areas: automotive electronics, modules, LED power drive modules, solar module junction boxes, electric vehicle charging column modules, lithium-ion battery packs, capacitor banks, magnetic induction coils, inverter power supplies.

epoxy resin

Color: Black or white fluid; Used for metal bonding, motor product iron core bonding, power reactor sealing, soft magnetic unit sealing, high-temperature sensor sealing, etc.

polyurethane

Color: Black liquid/white liquid, brownish yellow liquid/brownish yellow liquid; Application areas: Used for pouring and sealing communication equipment, transformers, control power supplies, ignition controllers, electronic sensors, etc.

2) Thermal conductive silicone grease

Color: White liquid; Thermal conductivity: 1.2-2.5W/m.K; Low settling, stored at room temperature; Application areas: power modules, integrated chips, power modules, automotive electronic products, telecommunications equipment, computers and their accessories.

3) Thermal conductive adhesive sealing silicone

Color: Cream white; Reduce mechanical stress and tension caused by mechanical, thermal shock, and vibration; Excellent electrical insulation performance and anti corona; Excellent outdoor aging resistance, with a service life of 20-30 years; Stable mechanical and electrical performance between -60-260 ℃; Application field: LED lamp sealing; Heat dissipation of automotive electronic components; PCB board and electronic component heat dissipation positioning and sealing; Gap filling of high-power charged devices.

4) Thermal conductive silicone sheet

Color: Gray; Low hardness; Application areas: Applied to power modules, integrated chips, power modules, automotive electronic products, telecommunications equipment, computers, and other accessories.

The application of silicone in power lithium battery systems

At present, there are two types of interface organic materials used in vehicle thermal management: thermal conductive gaskets and thermal conductive sealing materials. Cylindrical, square, and soft pack batteries, with different types of cells, use different forms of silicone for heat dissipation.

Silicone sheets are easy to use and do not require special equipment for production; When using sealing glue or silicone grease, specialized equipment is required for gluing or injection. In terms of application effectiveness, the following figure can be used to illustrate.

The softer the texture of the thermal conductive material, the closer it fits with fixed shaped devices such as the cooled parts and heat sinks, and the better the thermal conductivity effect.

1) Adhesive for cylindrical power lithium batteries

(1) Sealing between battery cells

Thermal conductive sealing silicone, with a flexible sealing adhesive layer and good shock absorption effect, plays a total role in delaying the rapid spread of thermal runaway in faulty batteries. The thermal conductivity coefficient can be adjusted, but the disadvantage is that the overall sealing significantly increases the weight of the battery pack and the entire vehicle, and increases costs. Relatively speaking, silicone has a lower density, and if this type of process is used, silicone is a good choice.

(2) Adhesive fixation at the bottom of cylindrical batteries

(3) The method of wrapping silicone sheets around the battery cell

2) Analysis of Adhesive for Square Power lithium battery

Regarding square batteries, organic silicon interface materials are mostly used between the bottom of the square battery and the system's heat dissipation structure, allowing for better contact between the battery and the heat dissipation structure.

(1) Battery shell bonding

(2) Connection between battery cells and aluminum shells

(3) Placing silicon film between aluminum shell battery cells

3) Analysis of Adhesive for Soft Pack Power lithium battery

Adhesion between battery cells

A patent for improving the utilization of silicone heat dissipation in cylindrical batteries

Among the three main types of batteries: cylindrical, square, and soft pack, due to the complex shape of the module, cylindrical batteries use silicone material for heat dissipation, which reduces efficiency in production. Therefore, there are few practical cases of using silicone heat dissipation in cylindrical batteries. The patent I recently saw happened to solve this problem.

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