CN110800388A - 复合材料 - Google Patents

复合材料 Download PDF

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CN110800388A
CN110800388A CN201880042558.2A CN201880042558A CN110800388A CN 110800388 A CN110800388 A CN 110800388A CN 201880042558 A CN201880042558 A CN 201880042558A CN 110800388 A CN110800388 A CN 110800388A
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composite material
metal
metal foam
composite
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CN110800388B (zh
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辛种民
柳东雨
金昭镇
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LG Chem Ltd
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    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00Constructional details common to different types of electric apparatus
    • H05K7/20Modifications to facilitate cooling, ventilating, or heating
    • H05K7/2039Modifications to facilitate cooling, ventilating, or heating characterised by the heat transfer by conduction from the heat generating element to a dissipating body
    • H05K7/20436Inner thermal coupling elements in heat dissipating housings, e.g. protrusions or depressions integrally formed in the housing
    • H05K7/20445Inner thermal coupling elements in heat dissipating housings, e.g. protrusions or depressions integrally formed in the housing the coupling element being an additional piece, e.g. thermal standoff
    • H05K7/20472Sheet interfaces
    • H05K7/20481Sheet interfaces characterised by the material composition exhibiting specific thermal properties
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/002Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/002Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
    • B22F7/004Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
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    • B32B15/00Layered products comprising a layer of metal
    • B32B15/04Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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    • B32B27/18Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00Use of ingredients characterised by shape
    • C08K7/22Expanded, porous or hollow particles
    • C08K7/24Expanded, porous or hollow particles inorganic
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00Details of semiconductor or other solid state devices
    • H01L23/34Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements
    • H01L23/36Selection of materials, or shaping, to facilitate cooling or heating, e.g. heatsinks
    • H01L23/373Cooling facilitated by selection of materials for the device or materials for thermal expansion adaptation, e.g. carbon
    • H01L23/3733Cooling facilitated by selection of materials for the device or materials for thermal expansion adaptation, e.g. carbon having a heterogeneous or anisotropic structure, e.g. powder or fibres in a matrix, wire mesh, porous structures
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00Details of semiconductor or other solid state devices
    • H01L23/34Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements
    • H01L23/36Selection of materials, or shaping, to facilitate cooling or heating, e.g. heatsinks
    • H01L23/373Cooling facilitated by selection of materials for the device or materials for thermal expansion adaptation, e.g. carbon
    • H01L23/3736Metallic materials
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00Details of semiconductor or other solid state devices
    • H01L23/34Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements
    • H01L23/36Selection of materials, or shaping, to facilitate cooling or heating, e.g. heatsinks
    • H01L23/373Cooling facilitated by selection of materials for the device or materials for thermal expansion adaptation, e.g. carbon
    • H01L23/3737Organic materials with or without a thermoconductive filler
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00Constructional details common to different types of electric apparatus
    • H05K7/20Modifications to facilitate cooling, ventilating, or heating
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00Constructional details common to different types of electric apparatus
    • H05K7/20Modifications to facilitate cooling, ventilating, or heating
    • H05K7/2039Modifications to facilitate cooling, ventilating, or heating characterised by the heat transfer by conduction from the heat generating element to a dissipating body
    • H05K7/20436Inner thermal coupling elements in heat dissipating housings, e.g. protrusions or depressions integrally formed in the housing
    • H05K7/20445Inner thermal coupling elements in heat dissipating housings, e.g. protrusions or depressions integrally formed in the housing the coupling element being an additional piece, e.g. thermal standoff
    • H05K7/20472Sheet interfaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • B22F7/04Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal
    • B22F2007/042Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal characterised by the layer forming method
    • B22F2007/045Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal characterised by the layer forming method accompanied by fusion or impregnation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • B22F7/04Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal
    • B22F2007/042Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal characterised by the layer forming method
    • B22F2007/047Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal characterised by the layer forming method non-pressurised baking of the paste or slurry containing metal powder
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04Impregnation, embedding, or binder material
    • B32B2260/046Synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10Inorganic particles
    • B32B2264/105Metal
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10Inorganic particles
    • B32B2264/107Ceramic
    • B32B2264/108Carbon, e.g. graphite particles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00Composition of foam
    • B32B2266/04Inorganic
    • B32B2266/045Metal
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/20Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/202Conductive
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/30Properties of the layers or laminate having particular thermal properties
    • B32B2307/302Conductive
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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Abstract

本申请可以提供这样的复合材料:其包含金属泡沫、聚合物组分和导电填料,在具有优异的热导率的同时具有其他优异的物理特性例如耐冲击性、可加工性和绝缘特性,并且还能够控制导电性特性。

Description

复合材料
技术领域
本申请要求基于于2017年7月6日提交的韩国专利申请第10-2017-0086012号的优先权权益,其公开内容通过引用整体并入本文。
本申请涉及复合材料。
背景技术
散热材料可以用于各种应用中。例如,电池和各种电子设备由于在运行期间产生热量,因此需要能够有效控制这种热量的材料。
作为具有良好散热特性的材料,已知具有良好热导率的陶瓷材料等,但是由于这样的材料的可加工性差,因此可以使用通过将表现出高热导率的陶瓷填料等共混入聚合物基体中而制造的复合材料。
然而,由于为了通过上述方法确保高热导率必须使用大量的填料组分,因此会出现各种问题。例如,在包含大量填料组分的材料的情况下,材料本身趋于变硬,并且在这种情况下,耐冲击性等劣化。
发明内容
技术问题
本申请涉及复合材料,并且在一个实例中旨在提供这样的复合材料或者用于制造其的方法:其在具有优异的热导率的同时确保其他优异的物理特性例如耐冲击性和可加工性,并且如果需要,能够控制电导率。
技术方案
本申请涉及复合材料。术语复合材料可以意指至少包含金属泡沫和聚合物组分的材料。
在本说明书中,术语金属泡沫或金属骨架意指包含金属或金属合金作为主要组分的多孔结构。在此,金属等作为主要组分的事实意指,基于金属泡沫或金属骨架的总重量,金属等的比率为55重量%或更大、60重量%或更大、65重量%或更大、70重量%或更大、75重量%或更大、80重量%或更大、85重量%或更大、90重量%或更大、或者95重量%或更大。作为主要组分包含在内的金属等的比率的上限没有特别限制,并且例如可以为100重量%、99重量%或98重量%左右。
在本说明书中,术语多孔特性可以意指孔隙率为至少10%或更大、20%或更大、30%或更大、40%或更大、50%或更大、60%或更大、70%或更大、75%或更大、或者80%或更大的情况。孔隙率的上限没有特别限制,并且可以为例如小于约100%、约99%或更小、或者大概约98%或更小。孔隙率可以以已知的方式通过计算金属泡沫等的密度来计算。
复合材料具有高的热导率,因此,其可以用作控制热量的材料,例如散热材料。
例如,复合材料的热导率可以为约0.4W/mK或更大、0.45W/mK或更大、0.5W/mK或更大、0.55W/mK或更大、0.6W/mK或更大、0.65W/mK或更大、0.7W/mK或更大、0.75W/mK或更大、0.8W/mK或更大、0.85W/mK或更大、0.9W/mK或更大、0.95W/mK或更大、1W/mK或更大、1.5W/mK或更大、2W/mK或更大、2.5W/mK或更大、3W/mK或更大、3.5W/mK或更大、4W/mK或更大、4.5W/mK或更大、5W/mK或更大。复合材料的热导率越高,复合材料的热控制功能可以越优异,热导率没有特别限制,并且在一个实例中,其可以为约100W/mk或更小、90W/mK或更小、80W/mK或更小、70W/mK或更小、60W/mK或更小、50W/mK或更小、40W/mK或更小、30W/mK或更小、20W/mK或更小、15W/mK或更小、10W/mK或更小、8W/mK或更小、或者大概6W/mK或更小。本说明书中提及的复合材料的热导率是根据以下描述的实施例的描述方法来测量的。
在本说明书中所提及的物理特性中,当测量温度影响相关的物理特性时,除非另有说明,否则所述物理特性是在室温下测量的物理特性。术语室温是未被加热或冷却的自然温度,其可以为例如在10℃至30℃范围内的任何温度,或者大概约23℃或约25℃的温度。
本申请的复合材料在具有如上所述优异的导热特性的同时,可以稳定地确保诸如可加工性和耐冲击性的其他特性,并且这样的效果可以通过本说明书中描述的内容来实现。
复合材料中包含的金属泡沫的形状没有特别限制,但是在一个实例中可以为膜状。在本申请的复合材料中,添加有至少存在于膜形式的金属泡沫的表面上或内部中的聚合物组分。图1是示出根据本申请的一个实例的复合材料的图。如图中所示,本申请的复合材料(20)可以包含金属泡沫(22),并且还可以包含在其中和/或在其表面上的聚合物组分(21)。在此,该图示出了聚合物组分(21)存在于内部和表面二者的情况,但是聚合物组分(21)也可以仅存在于金属泡沫(22)的内部或表面上的任一者上,并且即使其存在于金属泡沫(22)的内部,也可以仅填充在金属泡沫(22)的一部分中而不是其全部内部。
也就是说,聚合物组分可以在金属泡沫的至少一个表面上形成表面层,或者可以填充并存在于金属泡沫内部的空隙中,并且在一些情况下,其还可以在形成表面层的同时填充到金属泡沫中。在形成表面层的情况下,聚合物组分可以在金属泡沫的表面中的至少一个表面、一些表面或所有表面上形成表面层。在一个实例中,聚合物组分可以至少在作为金属泡沫的主表面的上表面和/或下表面上形成表面层。表面层可以形成为覆盖金属泡沫的整个表面,或者也可以形成为仅覆盖表面的一部分。
复合材料中的金属泡沫的孔隙率可以在约10%至99%的范围内。具有这种孔隙率的金属泡沫具有形成适当的传热网络的多孔金属骨架,因此即使施加少量的相关金属泡沫也可以确保优异的热导率。在另一个实例中,孔隙率可以为15%或更大、20%或更大、25%或更大、30%或更大、35%或更大、40%或更大、45%或更大、50%或更大、55%或更大、60%或更大、65%或更大、或者70%或更大,或者可以为98%或更小、95%或更小、90%或更小、85%或更小、或者80%或更小。
金属泡沫可以呈膜的形式。在这种情况下,在根据以下描述的方法制造复合材料时,可以考虑期望的热导率或厚度比等来调节膜的厚度。为了确保目标热导率,膜的厚度可以为例如约10μm或更大、约20μm或更大、约30μm或更大、约40μm或更大、约45μm或更大、约50μm或更大、约55μm或更大、约60μm或更大、约65μm或更大、约70μm或更大、约100μm或更大、约150μm或更大、约200μm或更大、约250μm或更大、约300μm或更大、约350μm或更大、约400μm或更大、约450μm或更大、或者约500μm或更大。膜的厚度的上限根据目的进行控制,其没有特别限制,但是可以为例如10mm或更小、5,000μm或更小、2,000μm或更小、1,500μm或更小、约1,000μm或更小、约900μm或更小、约800μm或更小、约700μm或更小、约600μm或更小、约500μm或更小、约400μm或更小、约300μm或更小、约200μm或更小、约150μm或更小、约100μm或更小、约90μm或更小、约80μm或更小、约70μm或更小、约60μm或更小、或者大概约55μm或更小。
在本说明书中,当相关目标的厚度不恒定时,厚度可以是目标的最小厚度、最大厚度或平均厚度。
金属泡沫可以是具有高热导率的材料。在一个实例中,金属泡沫可以包含具有以下热导率的金属或金属合金或者由其组成:约8W/mK或更大、约10W/mK或更大、约15W/mK或更大、约20W/mK或更大、约25W/mK或更大、约30W/mK或更大、约35W/mK或更大、约40W/mK或更大、约45W/mK或更大、约50W/mK或更大、约55W/mK或更大、约60W/mK或更大、约65W/mK或更大、约70W/mK或更大、约75W/mK或更大、约80W/mK或更大、约85W/mK或更大、或者约90W/mK或更大。热导率没有特别限制,例如,其可以为大概约1,000W/mk或更小,因为数值越高,则在施加少量金属泡沫的同时可以确保期望的热控制特性。
金属泡沫的骨架可以包含各种金属或金属合金,其中能够表现出上述范围内的热导率的材料可以选自这些金属或金属合金。这样的材料可以例示为选自铜、金、铂、银、铝、镍、锰、铁、钴、镁、钼、钨和锌的任何金属,或者其两种或更多种的合金等,但不限于此。
这样的金属泡沫是众所周知的,并且用于制备金属泡沫的各种方法也是众所周知的。在本申请中,可以应用这样的已知金属泡沫或通过已知方法制备的金属泡沫。
作为用于制备金属泡沫的方法,已知对成孔剂(例如盐)和金属复合材料进行烧结的方法、将金属涂覆在支撑体(例如聚合物泡沫)上并在该状态下对其进行烧结的方法、或浆料法等。此外,还可以通过作为本申请人的在先申请的韩国专利申请第2017-0086014号、第2017-0040971号、第2017-0040972号、第2016-0162154号、第2016-0162153号或第2016-0162152号等中公开的方法来制备金属泡沫。
金属泡沫也可以根据在先申请中描述的方法通过感应加热法来制备,其中金属泡沫可以至少包含导电磁性金属。在这种情况下,基于重量,金属泡沫可以包含30重量%或更多、35重量%或更多、40重量%或更多、45重量%或更多、或者50重量%或更多的导电磁性金属。在另一个实例中,金属泡沫中导电磁性金属的比率可以为约55重量%或更大、60重量%或更大、65重量%或更大、70重量%或更大、75重量%或更大、80重量%或更大、85重量%或更大、或者90重量%或更大。导电磁性金属的比率的上限没有特别限制,并且可以为例如小于约100重量%、或者为95重量%或更小。
在本申请中,术语导电磁性金属是具有预定的相对磁导率和电导率的金属,其可以意指能够产生使得该金属可以通过感应加热方法进行烧结的程度的热的金属。
在一个实例中,作为导电金属,可以使用相对磁导率为90或更大的金属。相对磁导率(μr)为相关材料的磁导率(μ)与真空中的磁导率(μ0)的比率(μ/μ0)。在另一个实例中,相对磁导率可以为95或更大、100或更大、110或更大、120或更大、130或更大、140或更大、150或更大、160或更大、170或更大、180或更大、190或更大、200或更大、210或更大、220或更大、230或更大、240或更大、250或更大、260或更大、270或更大、280或更大、290或更大、300或更大、310或更大、320或更大、330或更大、340或更大、350或更大、360或更大、370或更大、380或更大、390或更大、400或更大、410或更大、420或更大、430或更大、440或更大、450或更大、460或更大、470或更大、480或更大、490或更大、500或更大、510或更大、520或更大、530或更大、540或更大、550或更大、560或更大、570或更大、580或更大或者590或更大。相对磁导率越高,在以下描述的施加电磁场以感应加热时产生的热量越高,由此上限没有特别限制。在一个实例中,相对磁导率的上限可以为例如约300,000或更小。
导电磁性金属在20℃下的电导率可以为约8MS/m或更大、9MS/m或更大、10MS/m或更大、11MS/m或更大、12MS/m或更大、13MS/m或更大、或者14.5MS/m或更大。电导率的上限没有特别限制,例如,电导率可以为约30MS/m或更小、25MS/m或更小、或者20MS/m或更小。
这样的导电磁性金属的具体实例包括镍、铁或钴等,但不限于此。
如上所述,复合材料还包含存在于金属泡沫的表面上或金属泡沫的内部中的聚合物组分,其中这样的复合材料的总厚度(T)与金属泡沫的厚度(MT)的比率(T/MT)可以为3或更小、或者2.5或更小。在另一个实例中,该厚度比可以为约2或更小、1.5或更小、1.4或更小、1.3或更小、1.2或更小、1.15或更小、或者1.1或更小。该厚度比的下限没有特别限制,但是在一个实例中,其可以为约1或更大、约1.01或更大、约1.02或更大、约1.03或更大、约1.04或更大、约1.05或更大、或者约1.1或更大。在这样的厚度比下,可以提供在确保期望的热导率的同时具有优异的可加工性或耐冲击性等的复合材料。
对本申请的复合材料中包含的聚合物组分的种类没有特别限制,可以考虑例如复合材料的可加工性、耐冲击性、绝缘特性等来选择。适用于本申请的聚合物组分的实例可以包括选自以下的一者或更多者:已知的丙烯酸类树脂、有机硅树脂、环氧树脂、聚氨酯树脂、氨基树脂、各种橡胶树脂和酚树脂,但不限于此。在一个实例中,可以应用有机硅树脂如聚二甲基硅氧烷系列作为聚合物组分。
本申请的复合材料通过应用上述金属泡沫而在使确保热导率的组分的比率最小化的同时,可以确保优异的热导率,从而在不损害可加工性或耐冲击性等的情况下确保期望的物理特性。
在一个实例中,包含在复合材料中的聚合物组分的体积(PV)与金属泡沫的体积(MV)的比率(MV/PV)可以为10或更小。在另一个实例中,该比率(MW/PV)可以为9或更小、8或更小、7或更小、6或更小、5或更小、4或更小、3或更小、2或更小、1或更小、或者大概0.5或更小。体积比率的下限没有特别限制,其可以为例如大概约0.1。可以通过包含在复合材料中的聚合物组分和金属泡沫的重量以及相关组分的密度来计算体积比。
在另一个实例中,相对于整个复合材料的重量,复合材料中金属泡沫的含量可以为约3重量%或更大、约5重量%或更大、或者约10重量%或更大。此外,相对于整个复合材料的重量,金属泡沫填料的含量可以为例如约50重量%或更小、约40重量%或更小、或者大概约25重量%或更小。
在本申请的复合材料中,如上聚合物组分可以在金属泡沫的至少一个表面上形成表面层。
在这种情况下,根据目的控制表面层(聚合物表层)的厚度,其没有特别限制,但是可以为例如约300μm或更小、250μm或更小、200μm或更小、或者150μm或更小、约100μm或更小、约80μm或更小、约60μm或更小、约40μm或更小、约30μm或更小、约25μm或更小、约20μm或更小、约15μm或更小、约10μm或更小、或者大概约5μm或更小。表层的厚度可以为例如5μm或更大、10μm或更大、15μm或更大、20μm或更大、25μm或更大、30μm或更大、70μm或更大、或者大概100μm或更大。
聚合物组分还可以包含导电填料,例如,导电填料可以包含在填充金属泡沫的内部空隙的聚合物组分和/或表面层的聚合物组分中。由此,可以提供具有更好的导热特性的复合材料,并且还可以控制复合材料的导电性。图2是在表面层中存在导电填料的情况的实例。如图2中所示,本申请的复合材料(30)可以包含聚合物组分(31)、金属泡沫(32)和导电填料(35)。
在本申请中,术语导电填料可以意指在20℃下的电导率为约8MS/m或更大、9MS/m或更大、10MS/m或更大、11MS/m或更大、12MS/m或更大、13MS/m或更大、或者14.5MS/m或更大的颗粒。电导率的上限没有特别限制,其可以为例如约30MS/m或更小、25MS/m或更小、或者20MS/m或更小。
适用于本申请的导电填料的具体种类没有特别限制,只要其具有上述电导率即可,可以使用已知的金属填料、金属合金填料或基于碳的填料等。
填料的实例可以例示为导电金属,例如镍、铁、钴、银、铜、金、铝、钙、钨、锌、钼、铂、金、锂、铁、铂、锡、铅、钛、锰或铬的填料,或者其两种或更多种的合金的填料,或者诸如石墨、碳纤维、碳纳米管、石墨烯或石墨的填料,但不限于此。
填料的形状或比率没有特别限制。在一个实例中,填料的形状可以具有各种形状,例如大体球形形状、针形形状、板形形状、片形形状、树枝形形状或星形形状,但不特别限于所述形状。
在一个实例中,导电填料的平均粒径可以在0.001μm至80μm的范围内。在另一个实例中,填料的平均粒径可以为0.01μm或更大、0.1μm或更大、0.5μm或更大、1μm或更大、2μm或更大、3μm或更大、4μm或更大、5μm或更大、或者约6μm或更大。在另一个实例中,填料的平均粒径可以为约75μm或更小、约70μm或更小、约65μm或更小、约60μm或更小、约55μm或更小、约50μm或更小、约45μm或更小、约40μm或更小、约35μm或更小、约30μm或更小、约25μm或更小、约20μm或更小、约15μm或更小、约10μm或更小、或者约5μm或更小。
填料的比率可以在确保或不破坏期望特性的范围内进行调节。在一个实例中,填料可以以约80体积%或更小的体积比包含在复合材料中。在此,体积比是基于构成复合材料的各组分例如金属泡沫、聚合物组分和填料的重量和密度而计算的值。
在另一个实例中,体积比可以为约75体积%或更小、70体积%或更小、65体积%或更小、60体积%或更小、55体积%或更小、50体积%或更小、45体积%或更小、40体积%或更小、35体积%或更小、或者大概约30体积%或更小,或者可以为约1体积%或更大、2体积%或更大、3体积%或更大、4体积%或更大、或者大概约5体积%或更大。
在另一个实例中,相对于100重量份的聚合物组分,填料可以以约0.1重量份至50重量份的比率包含在复合材料中。在另一个实例中,该比率可以为约0.5重量份或更大、1重量份或更大、5重量份或更大、或者10重量份或更大,并且还可以为约45重量份或更小、40重量份或更小、35重量份或更小、30重量份或更小、25重量份或更小、20重量份或更小、或者大概15重量份或更小。
本申请还涉及用于制备如上形式的复合材料的方法。该方法可以包括以下步骤:在聚合物组合物存在于包含热导率为8W/mk或更大的金属或金属合金并且呈膜形式的金属泡沫的表面上的状态下,使该包含导电填料的可固化聚合物组合物固化。
应用于该方法中的金属泡沫或填料的细节如上所述,并且待制备的复合材料的具体事项也可以遵循如上所述的内容。
另一方面,对上面应用的聚合物组合物没有特别限制,只要其可以通过固化等形成上述聚合物组分即可,并且这样的聚合物组分在本领域中是众所周知的。
也就是说,例如,可以通过使用已知组分中具有适当粘度的材料通过已知方法进行固化来制备所述复合材料。
有益效果
本申请可以提供这样的复合材料:其包含金属泡沫、聚合物组分和导电填料,在具有优异的热导率的同时具有其他优异的物理特性例如耐冲击性、可加工性和绝缘特性,并且还能够控制导电性特性。
附图说明
图1和图2是本申请的示例性复合材料的示意图。
具体实施方式
在下文中,将通过实施例和比较例详细描述本申请,但是本申请的范围不限于以下实施例。
实施例1
金属泡沫是铜金属泡沫,其中使用厚度为大概约100μm并且孔隙率为大概约70%的膜状的铜泡沫。将铜金属泡沫用其中混合有平均粒径为4μm左右同时呈树枝形形状的铜粉末和热固性有机硅树脂(Dow Corning Co.,Sylgard 183kit聚二甲基硅氧烷)的溶液(铜粉末10重量%)浸渍,并使用涂覆器除去过量的组合物使得最终的复合材料为厚度大概约120μm的膜形式。随后,将材料在约120℃的烘箱中保持约20分钟并固化以制备复合材料。该复合材料的热导率为大概约2.765W/mK并且电阻为大概约0.36Ω/□。
通过获得复合材料的热扩散率(A)、比热(B)和密度(C)并将它们代入热导率=ABC的方程中来确定热导率,其中用激光闪光法(LFA设备,型号名称:LFA467)测量热扩散率,通过DSC(差示扫描量热仪)设备测量比热,并用阿基米德法测量密度。此外,热导率是相对于复合材料的厚度方向(Z轴)的值。此外,用4点探针系统的薄层电阻计测量电阻。
实施例2.
以与实施例1中相同的方式制备复合材料,不同之处在于将平均粒径为大概约10μm同时呈片形形状的铜粉末用作导电填料。该复合材料的热导率为大概约4.329W/mK并且电阻为0.32Ω/□左右。
实施例3.
以与实施例1中相同的方式制备复合材料,不同之处在于将平均粒径水平为约3μm至6μm左右同时呈球形形状的镍粉末用作导电填料。该复合材料的热导率为大概约1.741W/mK并且电阻为0.048Ω/□左右。
实施例4.
以与实施例1中相同的方式制备复合材料,不同之处在于将平均粒径水平为约3μm至6μm左右同时呈片形形状的镍粉末用作导电填料。该复合材料的热导率为大概约2.986W/mK并且电阻为0.041Ω/□左右。
实施例5.
以与实施例1中相同的方式制备复合材料,不同之处在于将平均粒径为约3μm至6μm左右同时呈片形形状的石墨粉末用作导电填料。该复合材料的热导率为大概约2.134W/mK并且电阻为约0.51Ω/□左右。
比较例1
使用膜涂覆器使热固性有机硅树脂(Dow Corning Co.,Sylgard 183kit聚二甲基硅氧烷)形成为120μm厚的膜。此后,通过将其在120℃的烘箱中加热20分钟来进行热固化。该复合材料的热导率为大概约0.270W/mK,并且测得的电阻与绝缘水平一样高。
比较例2
使用膜涂覆器将热固性有机硅树脂(Dow Corning Co.,Sylgard 183kit聚二甲基硅氧烷)涂覆在厚度为100μm并且孔隙率为75%的片型铜泡沫上以具有120μm的整体厚度。此后,通过将其在120℃的烘箱中加热20分钟来进行热固化以制备复合材料。该复合材料的热导率为大概约1.212W/mK,并且测得的电阻与绝缘水平一样高。
比较例3
使用膜涂覆器使以下溶液形成为120μm厚的膜,所述溶液通过将热固性有机硅树脂(Dow Corning Co.,Sylgard 183kit聚二甲基硅氧烷)与呈树枝形形状并且平均粒径为4μm的铜粉末的混合溶液(铜粉末:25重量%)混合来制备。此后,通过将其在120℃的烘箱中加热20分钟来进行热固化以制备散热复合材料。该复合材料的热导率为大概约0.402W/mK,并且测得的电阻与绝缘水平一样高。
比较例4
使用膜涂覆器使以下溶液形成为120μm厚的膜,所述溶液通过将热固性有机硅树脂(Dow Corning Co.,Sylgard 183kit聚二甲基硅氧烷)与呈片形形状并且平均粒径约10μm的铜粉末的混合溶液(铜粉末:25重量%)混合来制备。此后,通过将其在120℃的烘箱中加热20分钟来进行热固化以制备散热复合材料。该复合材料的热导率为大概约0.338W/mK,并且测得的电阻与绝缘水平一样高。
比较例5
使用膜涂覆器使以下溶液形成为120μm厚的膜,所述溶液通过将热固性有机硅树脂(Dow Corning Co.,Sylgard 183kit聚二甲基硅氧烷)与呈球形形状并且平均粒径约3μm至6μm左右的镍粉末的混合溶液(镍粉末:25重量%)混合来制备。此后,通过将其在120℃的烘箱中加热20分钟来进行热固化以制备散热复合材料。该复合材料的热导率为大概约0.297W/mK,并且测得的电阻与绝缘水平一样高。
比较例6
使用膜涂覆器使以下溶液形成为120μm厚的膜,所述溶液通过将热固性有机硅树脂(Dow Corning Co.,Sylgard 183kit聚二甲基硅氧烷)与呈片形形状并且平均粒径3μm至6μm左右的镍粉末的混合溶液(镍粉末:25重量%)混合来制备。此后,通过将其在120℃的烘箱中加热20分钟来进行热固化以制备散热复合材料。该复合材料的热导率为大概约0.301W/mK,并且测得的电阻与绝缘水平一样高。

Claims (17)

1.一种复合材料,包含膜形式的金属泡沫和聚合物组分,所述聚合物组分存在于所述金属泡沫的表面上或所述金属泡沫的内部并且包含导电填料。
2.根据权利要求1所述的复合材料,其中总厚度(T)与所述金属泡沫的厚度(MT)的比率(T/MT)为2.5或更小。
3.根据权利要求1所述的复合材料,其中总厚度(T)与所述金属泡沫的厚度(MT)的比率(T/MT)为1或更大。
4.根据权利要求1所述的复合材料,其中总厚度(T)与所述金属泡沫的厚度(MT)的比率(T/MT)为3或更小。
5.根据权利要求1所述的复合材料,其中所述金属泡沫包含热导率为8W/mK或更大的金属或金属合金。
6.根据权利要求1所述的导热性复合材料,其中所述金属泡沫的厚度为10μm或更大。
7.根据权利要求1所述的复合材料,其中所述金属泡沫的孔隙率在10%至99%的范围内。
8.根据权利要求1所述的复合材料,其中所述金属泡沫具有包含选自铜、金、铂、银、铝、镍、锰、铁、钴、镁、钼、钨和锌中的任一种金属或其两种或更多种的骨架。
9.根据权利要求1所述的复合材料,其中所述聚合物组分包含选自以下的一者或更多者:丙烯酸类树脂、有机硅树脂、环氧树脂、聚氨酯树脂、氨基树脂和酚树脂。
10.根据权利要求1所述的复合材料,其中所述聚合物组分的体积(PV)与所述金属泡沫的体积(MV)的比率(MV/PV)为10或更小。
11.根据权利要求1所述的复合材料,其中所述导电填料为金属填料、金属合金填料或基于碳的填料。
12.根据权利要求1所述的复合材料,其中所述导电填料为选自以下的一种或更多种填料:镍、铁、钴、银、铜、金、铝、钙、钨、锌、钼、铂、金、锂、铁、铂、锡、铅、钛、锰、镁和铬。
13.根据权利要求1所述的复合材料,其中所述导电填料为石墨、碳纤维、碳纳米管、石墨烯或石墨。
14.根据权利要求1所述的复合材料,其中所述导电填料具有球形形状、针形形状、板形形状、片形形状、树枝形形状或星形形状。
15.根据权利要求1所述的复合材料,其中所述导电填料的平均粒径在0.001μm至80μm的范围内。
16.根据权利要求1所述的复合材料,其中所述导电填料的体积比为80体积%或更小。
17.一种用于制备根据权利要求1所述的复合材料的方法,包括以下步骤:在包含导电填料的可固化聚合物组合物存在于包含金属或金属合金并且呈膜形式的金属泡沫的表面上的状态下,使所述聚合物组合物固化。
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