CN114728491A - 导热体及其制造方法 - Google Patents

导热体及其制造方法 Download PDF

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Publication number
CN114728491A
CN114728491A CN202080081177.2A CN202080081177A CN114728491A CN 114728491 A CN114728491 A CN 114728491A CN 202080081177 A CN202080081177 A CN 202080081177A CN 114728491 A CN114728491 A CN 114728491A
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China
Prior art keywords
heat
heat conductor
conductive material
porous structure
resin
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CN202080081177.2A
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English (en)
Inventor
铃木贵文
本田拓望
本间雅登
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Toray Industries Inc
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Toray Industries Inc
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Publication of CN114728491A publication Critical patent/CN114728491A/zh
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Abstract

本发明的目的是提供兼有优异的轻量性与优异的刚性、且散热性优异的导热体。为了达到上述目的，本发明的导热体具有以下构成。即，一种导热体，其是面内导热率为300W/m·K以上的片状的导热材料(II)被包含于由增强纤维和树脂制成的多孔质结构体(I)而成的。

Description

导热体及其制造方法
技术领域
本发明涉及导热体、使用该导热体而成的壳体、以及导热体的制造方法。
背景技术
近年来，关于汽车、航空器、电子设备等产业用制品，对轻量性的市场要求逐年提高。此外，随着发动机、电动机、处理机等的发热模块的高性能化，对散热性的市场要求也正在逐年提高。为了响应这样的要求，具有优异的轻量性和高导热率的成型品在各种产业用途中被广泛利用。其中，使具有高导热率的导热材料和具有优异的轻量性的轻量材料复合了的导热体除了优异的轻量性以外，还具有优异的散热性，因此期待在各制品中的有效地利用，进行了广泛研究。
在专利文献1中记载了叠层了导热材料和由纤维增强塑料形成的刚性保持材料的导热体的发明。认为通过将导热材料和由纤维增强塑料形成的刚性保持材料叠层，从而可以获得除了优异的导热性以外，还兼有优异的轻量性的导热体。
在专利文献2中记载了将石墨片的叠层体用树脂层进行被覆的、导热体的发明。认为通过由石墨片和树脂形成壳体从而除了优异的导热性以外，还可以兼有优异的轻量性。
在专利文献3中记载了使石墨片夹装在二个海绵层之间的导热体的发明。认为通过将石墨片夹装在二个海绵层之间，从而可以获得优异的导热性。
现有技术文献
专利文献
专利文献1：国际公开第2016/002457号
专利文献2：日本特开2006-95935号公报
专利文献3：国际公开第2018/198293号
发明内容
发明所要解决的课题
专利文献1中的导热体被认为通过将导热材料与刚性保持材料叠层，从而可以兼有优异的导热性与优异的轻量性，但刚性保持材料为致密的纤维增强塑料，具有轻量性的改善的余地。
专利文献2中的导热体被认为通过将石墨片的表面和端部用树脂进行被覆，从而可以兼有优异的导热性与优异的轻量性，但被覆石墨片的树脂为致密的树脂，具有轻量性的改善的余地。此外，由于通过非增强的树脂进行被覆，因此可以认为导热体的刚性低。
专利文献3中的导热体被认为通过使石墨片夹装在二个海绵层之间，从而具有优异的导热性。海绵层为发泡树脂，虽然轻量性优异，但是可以认为刚性非常低。
本发明是鉴于上述课题而提出的，其目的是提供兼有优异的轻量性与优异的刚性、且散热性优异的导热体。
用于解决课题的手段
为了解决上述课题，本发明的导热体具有以下构成。
一种导热体，其是面内导热率为300W/m·K以上的片状的导热材料(II)被包含于由增强纤维和树脂制成的多孔质结构体(I)而成的。
发明的效果
根据本发明，可以获得兼有优异的轻量性与优异的刚性、且散热性优异的导热体。
附图说明
图1为显示本发明的导热体的一实施方式的示意图
图2为显示本发明的导热体的其它实施方式的示意图
图3为显示从本发明的导热体的实施方式排除的一方式的示意图
图4为显示散热性评价的状况的示意图
具体实施方式
以下详细地说明本发明。
＜导热体＞
构成本发明的导热体的多孔质结构体(I)包含片状的导热材料(II)(以下，有时简称为导热材料(II))。这里所谓“包含”，是指导热材料(II)作为多孔质结构体(I)的层的一部分而存在。
例如，图1那样的、多孔质结构体(I)2覆盖导热材料(II)3的一端面(图1中的右侧的端面)和一个表面(图1中的上侧的表面)的方案、图2那样的、多孔质结构体(I)2覆盖导热材料(II)3的两面(两个表面)和全部端面即多孔质结构体(I)内包导热材料(II)的方案可以说多孔质结构体(I)包含导热材料(II)。另一方面，图3那样的导热材料(II)3的全部端面露出，即可视为仅导热材料(II)形成独立了的层的方案从上述“包含”的概念排除。这样，通过导热材料(II)包含于多孔质结构体(I)，从而多孔质结构体(I)承担施加于导热体的应力，可以抑制应力向导热材料(II)传递，抑制导热材料(II)的破坏。
多孔质结构体(I)优选覆盖导热材料(II)的至少两个端面，优选进一步覆盖导热材料(II)的两面，进一步优选覆盖导热材料(II)的两面和全部端面，即内包导热材料(II)。
需要说明的是，在本发明中，多孔质结构体(I)也可以经由粘接剂、缓冲材料等其它构件而覆盖导热材料(II)。此外，在多孔质结构体(I)与导热材料(II)之间也可以具有间隙。
然而，在本发明中，优选导热材料(II)的至少一个端面与多孔质结构体(I)不经由其它构件而直接相接。此外，优选导热材料(II)的至少一个表面与多孔质结构体(I)相接。通过这样导热材料(II)与多孔质结构体(I)直接相接，从而从导热体表面传递的热可以从多孔质结构体(I)向导热材料(II)迅速传递。
进一步，在本发明中，导热材料(II)优选不与多孔质结构体(I)粘接。为了使导热材料(II)与多孔质结构体(I)粘接，一般而言，需要使粘接剂介于它们之间，但与粘接剂对应地导热材料(II)在导热体中所占的比例减少，导热体的散热性降低。此外，通过导热材料(II)不与多孔质结构体(I)粘接，从而多孔质结构体(I)承担施加于导热体的应力的比例变大，因此可以抑制应力向导热材料(II)传递，抑制导热材料(II)的破坏。
本发明的导热体的弯曲弹性模量优选为3GPa以上，更优选为5GPa以上。对导热体的弯曲弹性模量的上限没有特别限制，但通常为20GPa左右。通过弯曲弹性模量为3GPa以上，从而导热体成为刚性的结构体，可以适合用于壳体等。作为用于使弯曲弹性模量为这样的范围的手段，可举出例如，使用由纤维增强树脂制成的多孔质结构体作为多孔质结构体(I)的方法。
本发明的导热体的每单位宽度的抗弯刚度优选为0.3N·m以上，更优选为0.5N·m以上，进一步优选为1.5N·m以上。导热体的每单位宽度的抗弯刚度越高越优选，因此对每单位宽度的抗弯刚度的上限没有特别限制，通常为45N·m左右。每单位宽度的抗弯刚度由导热体的弹性模量E(Pa)、截面惯性矩I(m4)、导热体的宽度b(m)，通过下式而算出。
·每单位宽度的抗弯刚度(N·m)＝E(Pa)×I(m4)/b(m)
此外，在导热体的截面为矩形截面的情况下，矩形截面的截面惯性矩I为bh3/12(m4)，因此可以通过下式而算出。
·每单位宽度的抗弯刚度(N·m)＝E(Pa)×h3(m3)/12
作为用于使每单位宽度的抗弯刚度为上述范围的手段，可举出例如，使用由纤维增强树脂制成的多孔质结构体作为多孔质结构体(I)的方法。此外，可举出例如，使导热体的厚度为厚壁的方法。
本发明的导热体的最大厚度优选为0.3mm以上且3.0mm以下，更优选为0.5mm以上且1.5mm以下。通过使导热体的厚度为薄壁从而具有轻量化的效果，但比0.3mm薄的导热体有时刚性不足。
本发明的导热体的比重优选为1.00以下，更优选为0.80以下，进一步优选为0.50以下。如果导热体的比重变小则轻量性优异，但如果比重变为0.10以下则有时刚性不足。
导热体的一部分表面、或全部表面也可以被树脂被覆。通过将导热体用树脂进行被覆，从而可以防止由增强纤维的露出引起的短路。此外，从设计性、机械特性的观点考虑也是优选的。
[导热材料(II)]
在本发明中，导热材料(II)为片状，其面内导热率为300W/m·K以上。导热材料(II)的面内导热率优选为500w/m·K以上，进一步优选为1000w/m·K以上。面内导热率越高越优选，因此对面内导热率的上限没有特别限制，但已知具有2000W/m·K左右的面内导热率的导热材料。如果导热材料(II)的面内导热率为300W/m·K以上，则导热体向面内方向的热的扩散优异，导热体的散热性优异。导热材料(II)的导热率可以通过激光闪光法在面内测定用的样品保持件放置样品，使样品的大小为直径20～30mm左右，使厚度为1mm以下从而测定。此外，对于不易吸收激光的材料，在样品表面薄而均匀地形成黑化膜。对于红外线检测元件的测温波长下的放射率低的材料，对样品背面进行同样的处理。此外，在本发明中，所谓片状，是指厚度薄而宽度宽的形状，是指厚度为0.01μm以上且10mm以下，且宽度与厚度的宽厚比为10以上的形状。
导热材料(II)的材质只要面内导热率成为300w/m·K以上，就没有特别限定，可以使用例如，陶瓷、金属、石墨、通过在树脂中添加高导热性填料从而提高了导热率的高导热性树脂等。
进一步，导热材料(II)优选包含选自石墨片、金属片和陶瓷片中的导热片，更优选由选自石墨片、金属片和陶瓷片中的导热片构成。作为陶瓷片，可以举出二氧化硅、氧化锆、氧化铝、氮化硼、碳化硅、氮化硅等的片。作为金属片，可以举出由钛、铝、镁、铁、银、金、铂、铜、镍、或以这些元素作为主成分的合金形成的片。
金属片比较便宜，其中铜片便宜且导热率也优异，因此从原料成本的观点考虑是优选的。石墨片由于比重小，并且导热率优异，因此从使导热体的轻量性、散热性提高的观点考虑，在本发明中是特别优选的。
作为石墨片，可以举出将石墨粉末与粘合剂树脂混合成型而得的片、或将膨胀石墨轧制而得的片、使用烃系气体通过CVD法使碳原子叠层在基板上后退火而得的片、将高分子化合物的膜进行石墨化而得的片等。其中，将高分子化合物的膜进行石墨化而得的片由于导热性非常高，因此是优选的。
在本发明中，导热材料(II)优选包含多个导热片的叠层结构体，更优选为多个导热片的叠层结构体。特别是，石墨片的片内的石墨烯结构的取向影响导热率，一般而言，薄的石墨片的导热率更高。因此，在使用石墨片作为导热片的情况下，通过使多片的叠层结构体为导热材料(II)，从而可以使导热体的散热性提高。在该情况下，优选构成导热材料(II)的多个导热片不经由粘接剂等而彼此直接接触。通过导热片彼此直接接触，从而可以使导热材料(II)在导热体中所占的比例增加，导热体的散热性提高。此外，通过导热片彼此直接接触，从而向面外方向的热的扩散也优异。导热片的叠层片数优选为2片以上且10片以下，更优选为3片以上且5片以下。如果使叠层片数增加，则导热体的散热性提高。另一方面，如果使叠层片数过度增加，则工艺性变低。
导热材料(II)的平均厚度优选为0.01μm以上且2.0mm以下，更优选为5μm以上且1.0mm以下，进一步优选为15μm以上且0.5mm以下。如果导热材料(II)的平均厚度过小，则导热体的散热性降低，如果导热材料(II)的平均厚度过大，则导热体的重量变重。导热材料(II)的平均厚度的测定方法是，使用测微计测定导热材料(II)的9点的厚度直到小数点后1位，将其平均值设为平均厚度。关于进行测定的点，分别以各测定点与邻近的点或样品端部的间隔在纵向和横向中成为均等间隔的方式对纵向和横向各3点共计9点进行测定。
[多孔质结构体(I)]
多孔质结构体(I)的材质只要是由增强纤维和树脂制成的纤维增强树脂，就没有特别限制，可举出例如，使包含发泡剂的树脂含浸于连续纤维并使其发泡而得的物质、使包含发泡剂的树脂含浸于不连续纤维并使其发泡而得的物质、或使树脂含浸于不连续纤维并通过不连续纤维的回弹而使其膨胀了的物质等。需要说明的是，所谓连续的增强纤维，是指沿至少一个方向以15mm以上、优选100mm以上的长度连续的增强纤维。通过为纤维增强树脂，从而在导热体的轻量性和刚性的观点上是有利的。此外，在使多孔质结构体(I)包含导热材料(II)时，通过多孔质结构体(I)沿面外方向崩溃、或膨胀，从而多孔质结构体(I)可以包含导热材料(II)而不发生导热材料(II)的位置偏移。
多孔质结构体(I)中的空隙的体积含有率相对于多孔质结构体(I)的表观体积优选为10％以上且85％以下，更优选为20％以上且85％以下，从兼有轻量性与机械特性的观点考虑进一步优选为50％以上且80％以下。
从导热体的轻量性的观点考虑，多孔质结构体(I)的比重优选为0.01～1.5。更优选为0.1～1.3，进一步优选为0.3～1.1。比重的测定是，切出多孔质结构体(I)，按照ISO0845(1988)进行测定。
对多孔质结构体(I)所包含的增强纤维的种类没有特别限制，可以使用例如，碳纤维、玻璃纤维、芳族聚酰胺纤维、氧化铝纤维、碳化硅纤维、硼纤维、金属纤维、天然纤维、矿物纤维等，它们可以使用1种或并用2种以上。其中，从比强度、比刚性高，轻量化效果的观点考虑，优选使用PAN系、沥青系、人造丝系等的碳纤维。此外，从提高所得的导热体的经济性的观点考虑，可以优选使用玻璃纤维，特别是从机械特性与经济性的平衡考虑优选并用碳纤维与玻璃纤维。进一步，从提高所得的导热体的冲击吸收性、赋形性的观点考虑，可以优选使用芳族聚酰胺纤维，特别是从机械特性与冲击吸收性的平衡考虑优选并用碳纤维与芳族聚酰胺纤维。此外，从提高所得的导热体的导电性的观点考虑，也可以使用被覆了镍、铜、镱等金属的增强纤维、沥青系的碳纤维。
增强纤维用上浆剂进行表面处理从机械特性提高的观点考虑是优选的。作为上浆剂，可举出多官能环氧树脂、丙烯酸系聚合物、多元醇、聚乙烯亚胺等，具体而言，可举出甘油三缩水甘油基醚、二甘油聚缩水甘油基醚、聚甘油聚缩水甘油基醚、山梨糖醇聚缩水甘油基醚、阿拉伯糖醇聚缩水甘油基醚、三羟甲基丙烷三缩水甘油基醚、季戊四醇聚缩水甘油基醚等脂肪族多元醇的聚缩水甘油基醚、聚丙烯酸、丙烯酸与甲基丙烯酸的共聚物、丙烯酸与马来酸的共聚物、或它们的2种以上的混合物、聚乙烯醇、甘油、二甘油、聚甘油、山梨糖醇、阿拉伯糖醇、三羟甲基丙烷、季戊四醇、1分子中包含更多氨基的聚乙烯亚胺等，它们之中，从1分子中包含大量反应性高的环氧基，并且水溶性高，涂布容易考虑，优选使用甘油三缩水甘油基醚、二甘油聚缩水甘油基醚、聚甘油聚缩水甘油基醚。
多孔质结构体(I)所包含的树脂没有特别限制，可以为热固性树脂也可以为热塑性树脂。热塑性树脂可举出例如，选自“聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸丁二醇酯(PBT)、聚对苯二甲酸丙二醇酯(PTT)、聚萘二甲酸乙二醇酯(PEN)、液晶聚酯等聚酯、聚乙烯(PE)、聚丙烯(PP)、聚丁烯等聚烯烃、聚甲醛(POM)、聚酰胺(PA)、聚苯硫醚(PPS)等聚芳撑硫醚、聚酮(PK)、聚醚酮(PEK)、聚醚醚酮(PEEK)、聚醚酮酮(PEKK)、聚醚腈(PEN)、聚四氟乙烯等氟系树脂”等结晶性树脂、“苯乙烯系树脂、以及聚碳酸酯(PC)、聚甲基丙烯酸甲酯(PMMA)、聚氯乙烯(PVC)、聚苯醚(PPE)、聚酰亚胺(PI)、聚酰胺酰亚胺(PAI)、聚醚酰亚胺(PEI)、聚砜(PSU)、聚醚砜、聚芳酯(PAR)”等非晶性树脂、以及酚系树脂、苯氧基树脂、进而聚苯乙烯系、聚烯烃系、聚氨酯系、聚酯系、聚酰胺系、聚丁二烯系、聚异戊二烯系、氟系树脂、和丙烯腈系等热塑性弹性体等、它们的共聚物和改性体等中的热塑性树脂。其中，从所得的导热体的轻量性的观点考虑聚烯烃是优选的。此外，从强度的观点考虑优选聚酰胺。特别是，在多孔质结构体(I)由纤维增强树脂制成的情况下，从增强纤维与树脂的界面接合强度的观点考虑优选聚酰胺。此外，热固性树脂可举出例如，不饱和聚酯树脂、乙烯基酯树脂、环氧树脂、酚(甲酚)树脂、脲树脂、三聚氰胺树脂、聚酰亚胺树脂、马来酰亚胺树脂、苯并
Figure BDA0003656460180000081
嗪树脂等、将它们的2种以上掺混而得的树脂等热固性树脂。其中，特别是，在多孔质结构体(I)由纤维增强树脂制成的情况下，从增强纤维与树脂的界面接合强度的观点考虑优选使用环氧树脂。
进一步，在树脂中，根据其用途而可以添加云母、滑石、高岭土、水滑石、绢云母、膨润土、硬硅钙石、海泡石、蒙皂石、蒙脱石、硅灰石、二氧化硅、碳酸钙、玻璃珠、玻璃薄片、玻璃微球、粘土、二硫化钼、氧化钛、氧化锌、氧化锑、多磷酸钙、石墨、硫酸钡、硫酸镁、硼酸锌、硼酸钙、硼酸铝晶须、钛酸钾晶须和高分子化合物等填充材料、金属系、金属氧化物系、炭黑和石墨粉末等导电性赋予材料、溴化树脂等卤素系阻燃剂、三氧化锑、五氧化二锑等锑系阻燃剂、多磷酸铵、芳香族磷酸酯和红磷等磷系阻燃剂、硼酸金属盐、羧酸金属盐和芳香族磺酰亚胺金属盐等有机酸金属盐系阻燃剂、硼酸锌、锌、氧化锌和锆化合物等无机系阻燃剂、氰脲酸、异氰脲酸、三聚氰胺、三聚氰胺氰脲酸盐、三聚氰胺磷酸盐和氮化胍等氮系阻燃剂、PTFE等氟系阻燃剂、聚有机硅氧烷等有机硅系阻燃剂、氢氧化铝、氢氧化镁等金属氢氧化物系阻燃剂、以及其它阻燃剂、氧化镉、氧化锌、氧化亚铜、氧化铜、氧化亚铁、氧化铁、氧化钴、氧化锰、氧化钼、氧化锡和氧化钛等阻燃助剂、颜料、染料、润滑剂、脱模剂、增容剂、分散剂、云母、滑石和高岭土等结晶成核剂、磷酸酯等增塑剂、热稳定剂、抗氧化剂、着色防止剂、紫外线吸收剂、流动性改性剂、发泡剂、抗菌剂、减振剂、防臭剂、滑动性改性剂、和聚醚酯酰胺等抗静电剂等。特别是，在用途为电气/电子设备、汽车、航空器等的情况下，有时要求阻燃性，优选添加磷系阻燃剂、氮系阻燃剂、无机系阻燃剂。
关于上述阻燃剂，为了表现阻燃效果，并且与所使用的树脂的机械特性、成型时的树脂流动性等保持良好的特性平衡，相对于树脂100质量份，优选使阻燃剂为1～20质量份。更优选为1～15质量份。
在本发明的导热体中，多孔质结构体(I)特别优选由不连续纤维增强树脂制成。不连续纤维增强树脂具有不连续纤维形成三维网络，并且不连续纤维彼此的交点通过树脂而被结合了的结构。通过不连续纤维彼此通过树脂而接合，从而多孔质结构体(I)的剪切弹性模量变高，导热体的刚性变高。以下，对该方案进行说明。
在不连续纤维增强树脂中，优选不连续纤维优选以小于500根的细纤度丝束的形式存在，更优选被分散成单纤维状而存在。不连续纤维的纤维长度优选为1～50mm，更优选为3～30mm。如果为1mm以上则可以高效率地发挥由不连续纤维带来的增强效果。此外，如果为50mm以下则可以良好地保持不连续纤维的分散。
相对于不连续纤维彼此交叉的全部交叉部分的个数，不连续纤维的单纤维彼此通过树脂而结合的结合部分的个数的比例为50％以上，更优选为70％以上，进一步优选为90％以上。
从兼有机械特性和成型性的观点考虑，不连续纤维的质量比例在多孔质结构体(I)中优选为5～60质量％，更优选为10～50质量％，进一步优选为15～40质量％。
在多孔质不连续纤维增强树脂中，不连续纤维优选其表面的30％以上、更优选50％以上，进一步优选80％以上被树脂被覆。通过为这样的被覆率，从而可以使多孔质结构体(I)的刚性高。被覆率通过用扫描型电子显微镜(SEM)，观察多孔质结构体(I)的截面而将增强纤维与树脂进行区别来测定。
多孔质不连续纤维增强树脂的空隙优选通过水银压入法而测定的平均孔隙直径为200μm以下。这样的平均孔隙直径优选为10μm以上且150μm以下，更优选为30μm以上且100μm以下。如果小于这样的范围则有时轻量化固化不充分，如果大于这样的范围则有时机械特性降低。所谓水银压入法，是使用水银压入孔隙度计进行的细孔径的测定方法，使水银以高压注入到样品，可以由施加的压力和被注入了的水银的量求出细孔径。平均孔隙直径可以通过下式而算出。
·平均孔隙直径(m)＝4×孔隙容积(m3/g)/比表面积(m2/g)
＜导热体的制造方法＞
本发明的导热体的制造方法是制造本发明的导热体的方法，其依次包含下述工序：在上述导热材料(II)的至少一个表面和至少一个端面配置多孔质结构体(I)的前体的工序；以及进行热压的工序。通过使用这样的方法，从而可以同时实施多孔质结构体(I)的成型/接合，因此生产性优异。在本发明的导热体的制造方法中，所谓“在导热材料(II)的至少一个表面和至少一个端面配置多孔质结构体(I)的前体”，是指多孔质结构体(I)的前体以覆盖导热材料(II)的至少一个表面和至少一个端面的方式配置。
在本发明的导热体的制造方法中，优选在导热材料(II)的两面配置多孔质结构体(I)的前体。此外，在本发明的导热体的制造方法中，多孔质结构体(I)的前体更优选被配置在导热材料(II)的至少两个端面，进一步优选进一步被配置在导热材料(II)的两面，特别优选被配置在导热材料(II)的两面和全部端面，即内包导热材料(II)。
在多孔质结构体(I)由不连续纤维增强树脂制成的情况下，多孔质结构体(I)的前体可以通过将热塑性树脂的膜、无纺织物压缩同时使其含浸于不连续增强纤维毡来制造。不连续增强纤维毡例如将不连续的增强纤维预先分散成纤维(strand)状、优选大致单纤维状、更优选单纤维状而制造。更具体而言，可以举出将不连续的增强纤维利用空气流进行分散而片化的气流成网法、将不连续的增强纤维一边机械地刨梳一边形成为片的梳棉法等干式工艺、基于将不连续的增强纤维在水中搅拌并抄纸的Radright法的湿式工艺作为公知技术。
作为使不连续的增强纤维更接近于单纤维状的手段，在干式工艺中，可以例示设置开纤棒的手段、使开纤棒振动的手段、使梳理机的齿精细的手段、调整梳理机的旋转速度的手段等，在湿式工艺中，可以例示调整不连续的增强纤维的搅拌条件的手段、将分散液的增强纤维浓度稀薄化的手段、调整分散液的粘度的手段、在移送分散液时抑制涡流的手段等。特别是，不连续增强纤维毡优选通过湿式法来制造，通过增加投入纤维的浓度、或调整分散液的流速(流量)和网格输送机的速度，从而可以容易地调整不连续增强纤维毡中的增强纤维的比例。例如，通过相对于分散液的流速，使网格输送机的速度慢，从而所得的不连续增强纤维毡中的纤维的取向难以朝向牵引方向，能够制造膨松的不连续增强纤维毡。作为不连续增强纤维毡，可以由不连续的增强纤维单独构成，也可以不连续的增强纤维与粉末形状、纤维形状的基体树脂成分混合，或不连续的增强纤维与有机化合物、无机化合物混合，或不连续的增强纤维彼此被树脂成分填塞。
使热塑性树脂的膜、无纺织物含浸于不连续增强纤维毡时的压力优选为0.5MPa以上且30MPa以下，更优选为1MPa以上且5MPa以下为好。如果压力小于0.5MPa则有时热塑性树脂未含浸于不连续增强纤维毡，此外如果大于30MPa则多孔质结构体的前体的厚度的调整变得困难。使热塑性树脂的膜、无纺织物含浸时的温度优选为热塑性树脂的熔点或玻璃化转变温度以上的温度，更优选为对熔点或玻璃化转变温度加上了10℃的温度以上，进一步优选为对熔点或玻璃化转变温度加上了20℃的温度以上。需要说明的是，在使热塑性树脂的膜、无纺织物含浸时的温度与热塑性树脂的熔点或玻璃化转变温度相比温度过高的情况下，有时发生热塑性树脂的分解、劣化，因此优选为对热塑性树脂的熔点或玻璃化转变温度加上了150℃的温度以下。
作为用于实现使热塑性树脂的膜、无纺织物含浸于不连续增强纤维毡的方法的设备，可以适合使用压缩成型机、双带压机。压缩成型机为间歇式，通过为并列了加热用和冷却用的2机以上的间歇式压制系统从而实现生产性的提高。双带压机为连续式，可以容易地进行连续的加工，因此连续生产性优异。
本发明的导热体的制造方法具有进行热压的工序。在该工序中，通过在导热材料(II)的至少一个表面和至少一个端面配置多孔质结构体(I)的前体，在多孔质结构体(I)的前体的膨胀温度或接合所需要的温度下热压，从而可以使导热材料包含于芯材。此时在使用了不连续增强纤维毡的情况下含浸于不连续增强纤维毡的树脂熔融或软化而使压缩状态释放，从而发生回弹。通过该回弹，形成微细的空隙而成为多孔质不连续纤维增强树脂。作为热压的设备，可以适合使用压缩成型机。压缩成型机为间歇式，通过为并列了加热用与冷却用的2机以上的间歇式压制系统从而可以实现生产性的提高。
＜壳体＞
本发明的壳体使用了本发明的导热体。通过利用本发明的导热体从而可以获得兼具优异的力学特性和轻量性的壳体。此外，从大量生产性的观点考虑也能够通过压制成型等的高循环成型进行成型，因此是优选的。
本发明的壳体例如可以通过上述导热体的制造方法，来制作所希望的壳体的形状的导热体从而获得。
实施例
以下，由实施例进一步详细地说明本发明。
(1)导热体的弯曲弹性模量测定
将制作出的导热体的弯曲试验片，按照ISO178法(1993)测定了弯曲特性。使测定数n＝5，将平均值设为弯曲弹性模量。作为测定装置，使用了インストロン·ジャパン(株)制，“インストロン”(注册商标)5565型万能材料试验机。
(2)导热体的散热性评价
如图4所示，在制作出的导热体1的背面四个角粘贴10mm×10mm的厚度3mm的橡胶制间隔物5，设置于实验台。在设置的导热体的表面一个角设置50mm×25mm的微陶瓷加热器4(坂口电热(株)制，微陶瓷加热器MS-2(商品名))，在恒定电流/恒定电压下，以10W将加热器进行了加热。由从加热器加热开始起15分钟后的加热器温度变为恒定时的加热器温度通过下述基准评价了散热性。
A：加热器温度小于130℃(散热性高)
B：加热器温度130℃以上(散热性低)
(参考例1)碳纤维束的制作
由以聚丙烯腈作为主成分的聚合物进行纺丝、烧成处理，获得了总长丝数12000根的碳纤维连续束。通过浸渍法向该碳纤维连续束施与上浆剂，在120℃的空气中干燥，获得了碳纤维束。该碳纤维束的特性如下所述。
单纤维直径：7μm
每单位长度的质量：0.8g/m
密度：1.8g/cm3
抗拉强度：4.2GPa
拉伸弹性模量：230GPa
上浆种类：聚氧乙烯油基醚
上浆附着量：1.5质量％
(参考例2)碳纤维毡的制作
将参考例1的碳纤维束用筒形切割机切割为纤维长度6mm，获得了短切碳纤维束。制作表面活性剂(ナカライテクス(株)制，聚氧乙烯月桂基醚(商品名))0.1质量％的水分散液，将该分散液和短切碳纤维束投入到抄纸机，制作出碳纤维毡。
抄纸机具备分散槽、抄纸槽、进而将分散槽与抄纸槽连接的输送部。分散槽附有搅拌机，能够分散所投入的分散液和短切碳纤维束。抄纸槽具备在底部具有抄纸面的网格输送机，将能够输送被抄纸而得的碳纤维毡的输送机与网格输送机连接。抄纸是使分散液中的纤维浓度为0.05质量％而进行。将抄纸而得的碳纤维毡用200℃的干燥炉干燥。接着，在通过输送机被输送的碳毡的上面部散布了粘结剂(日本触媒(株)制，“ポリメント”(注册商标)SK-1000)的3质量％的水分散液作为粘结剂。吸引剩余份的粘结剂，用200℃的干燥炉干燥，获得了碳纤维毡。所得的碳纤维毡的目付为50g/m2。
(参考例3)聚丙烯树脂膜的制作
将无改性聚丙烯树脂(プライムポリマー(株)制，“プライムポリプロ”(注册商标)J105G)90质量％、和酸改性聚丙烯树脂(三井化学(株)制，“アドマー”(注册商标)QE510)10质量％进行了掺混。将该掺混品用挤出机进行了熔融混炼后，从T字模头挤出。然后，用60℃的冷却辊牵引，将树脂冷却固化，从而获得了聚丙烯树脂膜。
(实施例1)
使用参考例2的碳纤维毡、参考例3的聚丙烯树脂膜、和石墨片(パナソニック(株)制，“PGS”(注册商标)EYGS182307，面内导热率1000W/m·K)，制作出导热体。将碳纤维毡、和聚丙烯树脂膜调整为50mm×150mm的尺寸，将石墨片调整为40mm×140mm的尺寸后，按照[聚丙烯树脂膜/碳纤维毡/聚丙烯树脂膜/碳纤维毡/石墨片/碳纤维毡/聚丙烯树脂膜/碳纤维毡/聚丙烯树脂膜]的顺序叠层。此时，石墨片配置在叠层体的中央。将该叠层体用脱模膜夹着，进一步用工具板夹着。将它们投入到盘面温度为180℃的压制成型机，在3MPa下热压10分钟，从而进行聚丙烯树脂向碳纤维毡的含浸。接下来，在工具板之间插入厚度1mm的间隔物，投入到盘面温度为40℃的压制成型机，以面压3MPa进行冷压直到叠层体冷却，从而获得了在导热材料的周围配置了多孔质结构体的导热体。用测微计测定了样品的厚度，结果厚度为1.0mm。通过在工具板之间插入厚度1mm的间隔物，从而聚丙烯树脂含浸了的碳纤维毡回弹，成为多孔质结构体。需要说明的是，本实施例中的样品为平板，因此厚度是恒定的。因此，在样品的任一点测定的厚度成为最大厚度。关于其它实施例、比较例也同样。此外，关于弯曲试验片，是将碳纤维毡、和聚丙烯树脂膜调整为50mm×40mm的尺寸，将石墨片调整为40mm×30mm的尺寸，除此以外，同样地操作，进行预成型、压制成型，获得了在导热材料的周围配置了多孔质结构体的、导热体的弯曲试验片。所得的导热体由于石墨片被包含增强纤维的多孔质结构体保护，因此显示优异的刚性、轻量性、散热性。
(实施例2)
变更聚丙烯树脂膜和碳纤维毡的片数，按照[聚丙烯树脂膜/碳纤维毡/石墨片/碳纤维毡/聚丙烯树脂膜/碳纤维毡/聚丙烯树脂膜]的顺序叠层，除此以外，与实施例1同样地操作，进行预成型、压制成型，获得了在导热材料的周围配置了多孔质结构体的、导热体、和导热体的弯曲试验片。所得的导热体由于在维持优异的刚性、散热性的状态下，空隙率增加了，因此显示更优异的轻量性。
(比较例1)
不叠层碳纤维毡，以叠层体的厚度成为1.0mm的方式，调整聚丙烯树脂膜的片数，将聚丙烯树脂膜和石墨片按照[聚丙烯树脂膜/石墨片/聚丙烯树脂膜]的顺序叠层，除此以外，与实施例1同样地操作，进行预成型、压制成型，获得了在导热材料的周围配置了聚丙烯树脂的、导热体、和导热体的弯曲试验片。所得的导热体由于石墨片被没有空隙的致密的树脂保护，因此轻量性差。此外，由于不包含增强纤维，因此刚性也低。
(比较例2)
使用石墨片、和发泡聚丙烯片(古川电机工业(株)制，“エフセル”(注册商标)RC2008W，密度0.46g/cm3)，将发泡聚丙烯片的厚度调整为0.5mm，按照[发泡聚丙烯片/石墨片/发泡聚丙烯片]的顺序叠层，除此以外，与实施例1同样地操作，进行预成型、压制成型，获得了在导热材料的周围配置了发泡聚丙烯的导热体。所得的导热体由于被发泡树脂保护，因此显示优异的轻量性，但刚性显著低。
(比较例3)
不叠层石墨片，除此以外，与实施例1同样地操作，进行预成型、压制成型，获得了不包含导热材料的导热体。此外，弯曲试验片制作时也同样地，不叠层石墨片，除此以外，与实施例1同样地操作，进行预成型、压制成型，获得了不包含导热材料的导热体的弯曲试验片。所得的导热体由于不包含导热材料，因此散热性低。
(比较例4)
将石墨片的尺寸调整为50×150mm的尺寸，除此以外，与实施例1同样地操作，进行预成型、压制成型，获得了导热材料的全部端部露出了的导热体。此外，弯曲试验片制作时，将石墨片调整为50mm×40mm的尺寸，除此以外，与实施例1同样地操作，进行预成型、压制成型，获得了导热材料的全部端部露出了的、导热体的弯曲试验片。所得的导热体由于石墨片的全部端部露出了，因此在石墨片的层间发生剥离而刚性降低了。
[表1]
Figure BDA0003656460180000171
产业可利用性
本发明的导热体可以兼有优异的轻量性与优异的刚性。因此，能够作为电气/电子设备、遥控设备(robots)、二轮车、汽车、航空器的结构构件等而在广泛的产业领域中应用。特别是，可以优选应用于要求高轻量性的便携式电子设备等的壳体。
符号的说明
1.导热体
2.多孔质结构体(I)
3.导热材料(II)
4.加热器
5.橡胶制间隔物。

Claims (12)

1.一种导热体，其是面内导热率为300W/m·K以上的片状的导热材料(II)被包含于由增强纤维和树脂制成的多孔质结构体(I)而成的。
2.根据权利要求1所述的导热体，所述多孔质结构体(I)覆盖所述导热材料(II)的至少两个端面。
3.根据权利要求2所述的导热体，所述多孔质结构体(I)覆盖所述导热材料(II)的两面和全部端面。
4.根据权利要求1～3中任一项所述的导热体，所述导热材料(II)包含选自石墨片、金属片和陶瓷片中的导热片。
5.根据权利要求4所述的导热体，所述导热材料(II)包含多个所述导热片的叠层结构体。
6.根据权利要求1～5中任一项所述的导热体，所述多孔质结构体(I)由不连续纤维增强树脂制成。
7.根据权利要求1～6中任一项所述的导热体，其弯曲弹性模量为3GPa以上。
8.根据权利要求1～7中任一项所述的导热体，其每单位宽度的抗弯刚度为0.3N·m以上。
9.根据权利要求1～8中任一项所述的导热体，其最大厚度为0.3mm以上且3.0mm以下。
10.根据权利要求1～9中任一项所述的导热体，其比重为1.00以下。
11.一种壳体，其是使用权利要求1～10中任一项所述的导热体而成的。
12.一种导热体的制造方法，是制造权利要求1～10中任一项所述的导热体的方法，其依次包含下述工序：在所述导热材料(II)的至少一个表面和至少一个端面配置多孔质结构体(I)的前体的工序；以及进行热压的工序。
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