CN115103867A - 包含硅烷封端的尿烷预聚物的基于聚氨酯的热界面材料 - Google Patents

包含硅烷封端的尿烷预聚物的基于聚氨酯的热界面材料 Download PDF

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CN115103867A
CN115103867A CN202180014867.0A CN202180014867A CN115103867A CN 115103867 A CN115103867 A CN 115103867A CN 202180014867 A CN202180014867 A CN 202180014867A CN 115103867 A CN115103867 A CN 115103867A
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thermal interface
silane
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terminated urethane
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S·格伦德
F·阿迪宗
D·施耐德
A·卢茨
N·希尔斯海姆
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Abstract

本文公开了热界面材料(TIM)组合物，其包含：a)非反应性聚氨酯预聚物；b)约70‑95wt％的三氢氧化铝(ATH)；c)约0.15‑1.5wt％的至少一种硅烷封端的尿烷预聚物；和d)约1‑20wt％的至少一种增塑剂，其中该热界面材料的总重量合计为100wt％。

Description

包含硅烷封端的尿烷预聚物的基于聚氨酯的热界面材料
技术领域
本公开涉及热界面材料及其在电池驱动的车辆中的用途。
背景技术
与传统的出行方式相比，电池驱动的车辆提供了显著优势，如重量轻、CO2排放减少等。然而，为了确保技术的最佳使用，仍然需要克服许多技术问题。例如，工业中当前的一种努力是通过开发密度更高的电池来增加电池驱动的车辆的行驶里程。而这导致需要为高密度电池开发更好的热管理系统。
在电池驱动的车辆中，电池单元或模块通过热界面材料(TIM)热连接至冷却单元。此类TIM典型地由填充有导热填料的聚合材料形成。为了实现2W/m·K或更高的热导率，可以使用具有100W/m·K或更高的热导率的填料，如氮化硼或铝粉。然而，此类填料是昂贵且磨损性的。较便宜且非磨损性的替代品是三氢氧化铝(ATH)，并且已经证实，获得具有高ATH负载量的基于聚氨酯的TIM是可实现的，其具有高热导率和低粘度。然而，发现当将此种TIM在气候条件下放置在竖直位置时，其倾向于滑动。因此，仍然需要改进来解决这一滑动问题。
发明内容
本文提供了热界面材料组合物，其包含：a)非反应性聚氨酯预聚物，该非反应性聚氨酯预聚物i)是至少一种多异氰酸酯和至少一种含羟基化合物的反应产物，并且ii)基本上不含残余异氰酸酯基团；b)约70-95wt％的三氢氧化铝；c)约0.15-1.5wt％的至少一种硅烷封端的尿烷预聚物；和d)约1-20wt％的至少一种增塑剂，其中热界面材料的总重量合计为100wt％。
在热界面材料组合物的一个实施例中，基于该组合物的总重量，非反应性聚氨酯预聚物以约1-25wt％的水平存在。
在热界面材料组合物的另一个实施例中，基于该组合物的总重量，硅烷封端的尿烷预聚物以约0.15-1.2wt％的水平存在。
在热界面材料组合物的又另一个实施例中，基于该组合物的总重量，硅烷封端的尿烷预聚物以约0.2-0.8wt％的水平存在。
在热界面材料组合物的又另一个实施例中，硅烷封端的尿烷预聚物选自至少一种异氰酸酯官能化的硅烷与一种或多种多元醇的反应产物、至少一种异氰酸酯官能化的硅烷与一种或多种羟基封端的预聚物的反应产物、和至少一种亲核体官能化的硅烷与一种或多种异氰酸酯封端的预聚物的反应产物。
在热界面材料组合物的又另一个实施例中，硅烷封端的尿烷预聚物具有范围为约200-5000的分子量。
在热界面材料组合物的又另一个实施例中，硅烷封端的尿烷预聚物具有范围为约300-3000的分子量。
在热界面材料组合物的又另一个实施例中，硅烷封端的尿烷预聚物具有范围为约500-2000的分子量。
本文进一步提供了制品，这些制品包含以上提供的热界面材料组合物。
在制品的一个实施例中，制品进一步包括由一个或多个电池单元、和冷却单元形成的电池模块，其中，电池模块通过热界面材料组合物连接至冷却单元。
具体实施方式
本文公开了热界面材料(TIM)组合物，其包含：a)非反应性聚氨酯预聚物；b)约70-95wt％的三氢氧化铝(ATH)；c)约0.15-1.5wt％的至少一种硅烷封端的尿烷预聚物；和d)约1-20wt％的至少一种增塑剂，其中热界面材料的总重量合计为100wt％。
根据本公开，本文使用的非反应性聚氨酯预聚物是至少一种多异氰酸酯和至少一种含羟基化合物的反应产物。此外，本文使用的非反应性聚氨酯预聚物基本上不含残余异氰酸酯基团，即预聚物中存在小于约0.8wt％或小于约0.4wt％的残余异氰酸酯基团。
根据本公开，本文使用的多异氰酸酯是多官能异氰酸酯(例如二异氰酸酯和三异氰酸酯)，并且可以是脂肪族、脂环族或芳香族的多异氰酸酯。本文使用的示例性的多官能异氰酸酯包括但不限于：亚乙基二异氰酸酯；六亚甲基-1,6-二异氰酸酯(HDI)；异佛尔酮二异氰酸酯(IPDI)；4,4’-、2,2’-和2,4’-二环己基甲烷二异氰酸酯(H12MDI)；降冰片烯二异氰酸酯；1,3-和1,4-(双异氰酸基甲基)环己烷(包括其顺式或反式异构体)；四亚甲基-1,4-二异氰酸酯(TMXDI)；1,12-十二烷二异氰酸酯；2,2,4-三甲基六亚甲基二异氰酸酯；2,2’-、2,4’-和4,4’-二苯基甲烷二异氰酸酯(MDI)；碳二亚胺改性的MDI；2,4-和2,6-甲苯二异氰酸酯(TDI)；1,3-和1,4-亚苯基二异氰酸酯；1,5-亚萘基二异氰酸酯；三苯基甲烷-4,4',4"-三异氰酸酯；聚苯基聚亚甲基多异氰酸酯；等。在一个实施例中，本文使用的多异氰酸酯是脂肪族多异氰酸酯。在另一个实施例中，本文使用的多异氰酸酯选自六亚甲基-1,6-二异氰酸酯；异佛尔酮二异氰酸酯；1,3-(双异氰酸基甲基)环己烷；1,4-(双异氰酸基甲基)环己烷；或其两种或更多种的混合物。在又另一个实施例中，本文使用的多异氰酸酯是六亚甲基-1,6-二异氰酸酯。
多异氰酸酯可以具有约10％-60％的NCO百分比量。在某些实施例中，本文使用的多异氰酸酯的平均异氰酸酯官能度可以为至少约2、或至少约2.2、或至少约2.4；且不大于约4、或不大于约3.5、或不大于约3。在另一个实施例中，多异氰酸酯的当量重量可以是至少约100、或至少约110、或至少约120；并且可以是不大于约300、或不大于约250、或不大于约200。
本文使用的含羟基化合物可以含有一个或多个羟基，如单醇、二醇、三醇或多元醇。示例性的含羟基化合物包括但不限于聚醚多元醇、聚酯多元醇、聚碳酸酯多元醇、醇等。在一个实施例中，含羟基化合物是含有一个或多个末端羟基的聚醚，即聚醚多元醇。本文使用的示例性的聚醚多元醇包括但不限于i)单醇，如烷氧基化的醇(其中烷氧基化剂是环氧乙烷、环氧丙烷、或环氧丁烷，并且引发醇是甲醇、乙醇、丁醇或更长的脂肪族醇)或基于脂肪酸的醇；ii)二醇，如1,4-丁二醇；iii)基于聚环氧乙烷、聚环氧丙烷、或聚环氧丁烷的聚醚多元醇；等。本文使用的含羟基化合物可以具有约1-7、或约1-5、或约1-3、或约1-2的官能度，以及约90-5000、或约90-3000、或约90-2000的分子量。
在制备非反应性聚氨酯预聚物时，除了多异氰酸酯和含羟基化合物，还可以添加附加的添加剂。这些添加剂包括催化剂、扩链剂、交联剂、填料、水分清除剂、着色剂等。特别地，大量的脂肪族和芳香族胺(例如二氨基二环辛烷、1,4-二氮杂二环[2.2.2]辛烷(DABCO)等)、有机金属化合物(例如二月桂酸二丁基锡(DBTDL)、二乙酸二丁基锡)、羧酸的碱金属盐和酚(己酸、辛酸、环烷酸、亚麻酸的钙盐、镁盐、锶盐、钡盐)可以用作催化剂。
另外，为了获得基本上不含残余异氰酸酯基团的非反应性聚氨酯预聚物，需要在反应中使用化学计量量或过量化学计量量的含羟基化合物，即含羟基化合物中的-OH基团与多异氰酸酯中的-NCO基团之间的比率大于或等于1。非反应性聚氨酯预聚物的制备包括：将至少一种多异氰酸酯、至少一种含羟基化合物和其他添加剂(如催化剂)混合在一起；在氮气氛下或在真空下在约20℃-80℃下搅拌反应混合物约10-60min；将反应产物冷却至室温；以及将反应产物放置并储存在密封容器中。
本文使用的非反应性聚氨酯预聚物可以具有范围为约2,000-50,000g/mol、或约3,000-30,000g/mol、或约4,000-15,000g/mol的分子量。
根据本公开，基于TIM组合物的总重量，非反应性聚氨酯预聚物可以以约1-25wt％、或约2-20wt％、或约5-15wt％的水平包含在该组合物中。
本文使用的ATH可以是单峰ATH粉末或具有多峰粒度分布(例如双峰、三峰等)的ATH粉末。当使用单峰ATH粉末时，平均粒度可以在约5-100μm的范围内。并且当使用多峰ATH粉末时，最小颗粒的平均粒度可以小于约10μm，而最大颗粒的平均粒度可以大于约50μm。另外，本文使用的ATH粉末也可以用硅烷、钛酸盐、羧酸盐等进行表面处理。
根据本公开，ATH粉末可以以约70-95wt％、或约75-90wt％、或约80-85wt％的水平包含在组合物中。
硅烷封端的尿烷预聚物是其中异氰酸酯基团中的一些或所有被有机硅烷封端的尿烷预聚物。硅烷封端的尿烷预聚物可以通过使至少一种异氰酸酯官能化的硅烷与一种或多种多元醇反应、或使至少一种异氰酸酯官能化的硅烷与一种或多种羟基封端的预聚物反应、或使至少一种亲核体官能化的硅烷(例如氨基硅烷、巯基硅烷等)与一种或多种异氰酸酯封端的预聚物反应来制备。预聚物可以选自由以下组成的组：聚氨酯、聚脲、聚醚、聚酯、聚(甲基)丙烯酸酯、聚碳酸酯、聚苯乙烯、聚胺或聚酰胺、聚乙烯酯、苯乙烯/丁二烯共聚物、聚烯烃、聚硅氧烷、和聚硅氧烷-脲/尿烷共聚物。本文使用的硅烷封端的尿烷预聚物可以范围为约200-5000、或约300-3000、或约500-2000的分子量。
合适的硅烷封端的尿烷预聚物可以是以下中公开的那些中的任一种：EP 1924621以及美国专利号3,933,756；5,756,751；6,288,198；6,545,087；6,703,453；6,809,170；6,833,423；6,844,413；6,887,964；6,998,459；7,115,696；7,465,778；7,060,750；和7,309,753，将这些专利通过引用并入本文。合适的硅烷封端的尿烷预聚物还是可商购的。例如，它们可以从科思创公司(Covestro)以商品名DesmosealTM、或从钟渊化学公司(Kaneka)以商品名MS PolymerTM、或从迈图公司(Momentive)以商品名SPUR+*获得。
根据本公开，基于TIM组合物的总重量，至少一种硅烷封端的尿烷预聚物可以以约0.15-1.5wt％、或约0.15-1.2wt％、或约0.2-0.8wt％的水平包含在该组合物中。
本文公开的TIM组合物进一步包含基于该组合物的总重量约1-20wt％、或约2-15wt％、或约3-10wt％的至少一种增塑剂。增塑剂是本领域所熟知的，并且本领域技术人员有能力根据如相容性和所希望的最终组合物的特性(例如粘度)等参数选择合适的增塑剂。
通常，合适的增塑剂包括酸和酐如己二酸、壬二酸、苯甲酸、柠檬酸、二聚酸、富马酸、异丁酸、间苯二甲酸、月桂酸、亚油酸、马来酸、马来酸酐、蜂花酸、肉豆蔻酸、油酸、棕榈酸、磷酸、邻苯二甲酸、蓖麻油酸、癸二酸、硬脂酸、琥珀酸、1,2-苯二甲酸等及其混合物的酯衍生物。同样合适的是环氧化油、甘油衍生物、石蜡衍生物、磺酸衍生物等，及其混合物以及其与前述衍生物的混合物。此类增塑剂的具体实例包括己二酸二乙基己基酯、己二酸庚基壬基酯、己二酸二异癸酯、己二酸聚酯、己二酸二辛酯、壬二酸二甲酯、二乙二醇二苯甲酸酯和二丙二醇二苯甲酸酯、聚乙二醇二苯甲酸酯、2,2,4-三甲基-1,3-戊二醇单异丁酸酯苯甲酸酯、2,2,4-三甲基-1,3-戊二醇二异丁酸酯、甲基(或乙基、或丁基)邻苯二甲酰乙基乙醇酸酯、柠檬酸三乙酯、富马酸二丁酯、2,2,4-三甲基-1,3-戊二醇二异丁酸酯、月桂酸甲酯、亚油酸甲酯、马来酸二正丁酯、偏苯三酸三辛酯、偏苯三酸庚基壬基酯、偏苯三酸三异癸基酯、偏苯三酸三异壬基酯、肉豆蔻酸异丙酯、油酸丁酯、棕榈酸甲酯、磷酸三甲苯酯、邻苯二甲酸二甲酯、邻苯二甲酸二乙酯、邻苯二甲酸二丁酯、邻苯二甲酸二异丁酯、邻苯二甲酸双-2-乙基己基酯、邻苯二甲酸辛基癸基酯、邻苯二甲酸二异癸酯、邻苯二甲酸庚基壬基酯、邻苯二甲酸双十一烷基酯、邻苯二甲酸双十三烷酯、邻苯二甲酸二环己酯、邻苯二甲酸二苯酯、邻苯二甲酸丁基苄基酯(如邻苯二甲酸的正丁基苄基酯)、邻苯二甲酸异癸基苄基酯、邻苯二甲酸烷基(C7/C9)苄基酯、邻苯二甲酸二甲氧基乙基酯、邻苯二甲酸7-(2,6,6,8-四甲基-4-氧杂-3-氧代-壬基)苄基酯、癸二酸二-2-乙基己基酯、蓖麻油酸丁酯、癸二酸二甲酯、硬脂酸甲酯、琥珀酸二乙酯、1,2-苯二甲酸的丁基苯基甲基酯、环氧化亚麻籽油、三乙酸甘油酯、具有约40％至约70％的Cl的氯化石蜡、邻，对甲苯磺酰胺、N-乙基对甲苯磺酰胺、N-环己基对甲苯磺酰胺、磺酰胺-甲醛树脂、及其混合物。本领域技术人员已知的其他合适的增塑剂包括蓖麻油、芳香族石油浓缩物、部分氢化的三联苯、硅酮增塑剂(如聚二甲基硅氧烷共聚多元醇酯、聚二甲基硅氧烷醇酯、硅酮羧酸酯)、格尔伯特酯等，单独或作为与其他增塑剂的混合物。
此外，可以将最高达约10wt％、或约1-10wt％、或约2-7wt％、或约2-5wt％的沉淀碳酸钙添加到TIM组合物中。不拘于任何特定的理论，据信添加任选的沉淀碳酸钙可以提高ATH的抗沉降性。
此外，本文公开的TIM组合物可以任选地进一步包含其他合适的添加剂，如催化剂、稳定剂、粘结促进剂、填料、着色剂等。此类任选的添加剂可以以基于TIM组合物的总重量高达约10wt％、或高达约8wt％、或高达约5wt％的水平存在。
如以下通过实例所证实的，当竖直放置时，不含硅烷封端的尿烷预聚物的TIM在暴露于气候条件后有滑动的趋势，而在TIM组合物中添加大于0.1wt％的硅烷封端的尿烷预聚物解决了滑动问题。此外，示出在没有增塑剂的情况下，TIM太粘而无法使用。
本文进一步公开了电池组系统，其中冷却单元或板通过以上所述的TIM组合物耦接到电池模块(由一个或多个电池单元形成)，使得可以在其间传导热量。在一个实施例中，电池组系统是在电池驱动的车辆中使用的那些系统。
实例
材料
·HDI-六亚甲基-1,6-二异氰酸酯(HDI)，从科思创公司以商品名DesmodurTM H获得；
·单醇-C12-C14脂肪醇引发的完全丙氧基化的(用环氧丙烷)单醇(MW：935g/mol，OH数：60.4，当量重量：927)，从陶氏公司(Dow,Inc.)获得；
·多元醇-聚环氧丙烷多元醇(官能度：2，MW：1000g/mol)，从陶氏公司获得；
·催化剂-二月桂酸二丁基锡(DBTDL)，从赢创公司(Evonik)以商品名DABCOTM T-12获得；
·STP-脂肪族硅烷封端的尿烷预聚物，从科思创公司以商品名DesmosealTM S XP2636获得；
·增塑剂-三油酸三羟甲基丙烷酯；
·ATH-双峰分布的三氢氧化铝，其中小颗粒的平均粒度小于10μm并且大颗粒的平均粒度大于50μm；
·聚酯多元醇-1-熔点为65℃的聚酯多元醇，从赢创公司以商品名DynacolTM 7381获得；
·聚酯多元醇-2-熔点为45℃的聚酯多元醇，从柏斯托公司(Perstorp)获得；
·聚酯尿烷预聚物-4,4’-二苯基甲烷二异氰酸酯与聚酯多元醇(聚酯多元醇-1)在邻苯二甲酸二异壬酯存在下的反应产物；
·硅烷-乙烯基三甲氧基硅烷。
非反应性聚氨酯预聚物
非反应性聚氨酯预聚物Pre-1和Pre-2如下制备：在反应器中，混合如表1中列出的除催化剂以外的所有组分；将反应器加热至60℃；向混合物中添加催化剂；在80℃下在氮气氛下搅拌混合物持续45min，并且然后在真空下搅拌10min；将无色的反应产物冷却至室温；以及将产物转移至容器中。通过凝胶渗透色谱法(GPC)使用马尔文帕纳科公司(MalvernPanalytical)的Viscotek GPCmax测量Pre-1和Pre-2的质量加权分子量(Mw)和多分散性指数(PDI)。
表1
Figure BDA0003799592300000081
对比实例CE1-CE5和实例E1-E7
样品制备
在对比实例CE1-CE5和实例E1-E7的每一个中，将如表2中列出的所有组分(首先是液体组分，然后是固体组分)添加到行星式混合器或双不对称离心机中，在真空下混合约30min，并且然后将所得TIM(呈糊剂形式)转移到筒、桶、或圆筒中以进行储存。
热导率
根据ASTM 5470，使用来自ZFW Stuttgart公司的TIM测试仪测量每个样品中获得的TIM糊剂的热导率。以Spaltplus模式在1.8-1.2mm厚度之间进行测量，并记录绝对热导率λ(W/m K)。
压入力
使用张力计(兹韦克公司(Zwick))测量每个样品中TIM糊剂的压入力。将每个样品的TIM糊剂放置在金属表面上。将直径为40mm的铝活塞放置在样品糊剂顶部，并将样品糊剂压缩至5mm(初始厚度)。然后，以1mm/s的速度将样品糊剂进一步压缩至0.3mm的厚度，并记录力挠曲曲线。将在0.5mm厚度处的力(N)记录为压入力。
粘度
在23℃下，在具有板-板几何形状(25mm直径的平行板)的流变仪上通过旋转流变学测量粘度。将剪切速率从0.001 1/s驱动至20 1/s，并且报告在10 1/s时的粘度。初始粘度是在施加TIM后直接测量的，而7天气候变化后的粘度是TIM暴露于气候变化条件7天后的粘度，在气候变化条件中，每个循环花费12小时完成，并且由在-40℃下4小时(非受控湿度)、4小时调节温度至80℃以及在80℃下4小时(80w％的相对湿度)组成。
滑动测试
在滑动测试期间，将TIM的每个样品放置在两个基板(电镀的钢基板和玻璃基板)之间，而压缩的TIM的厚度用间隔件控制在约3mm。然后将夹层样品在气候室中以20°的角度暴露于气候变化条件下持续4周。其后，观察样品的滑动和裂纹形成。
如本文中通过E1-E7所证实的，通过添加0.25wt％或更多的STP，TIM并未展现可见的裂纹，并且展现出小于1mm的滑动。此外，如CE4所示，缺乏增塑剂会导致TIM组合物具有太高的粘度而难以使用。
Figure BDA0003799592300000101

Claims (10)

1.一种热界面材料组合物，其包含：
a)非反应性聚氨酯预聚物，所述非反应性聚氨酯预聚物i)是至少一种多异氰酸酯和至少一种含羟基化合物的反应产物，并且ii)基本上不含残余异氰酸酯基团；
b)约70-95wt％的三氢氧化铝；
c)约0.15-1.5wt％的至少一种硅烷封端的尿烷预聚物；以及
d)约1-20wt％的至少一种增塑剂，
其中所述热界面材料的总重量总计达100wt％。
2.如权利要求1所述的热界面材料组合物，其中，基于所述组合物的总重量，所述非反应性聚氨酯预聚物以约1-25wt％的水平存在。
3.如权利要求1所述的热界面材料组合物，其中，基于所述组合物的总重量，所述硅烷封端的尿烷预聚物以约0.15-1.2wt％的水平存在。
4.如权利要求3所述的热界面材料组合物，其中，基于所述组合物的总重量，所述硅烷封端的尿烷预聚物以约0.2-0.8wt％的水平存在。
5.如权利要求1所述的热界面材料组合物，其中，所述硅烷封端的尿烷预聚物选自至少一种异氰酸酯官能化的硅烷与一种或多种多元醇的反应产物、至少一种异氰酸酯官能化的硅烷与一种或多种羟基封端的预聚物的反应产物、和至少一种亲核体官能化的硅烷与一种或多种异氰酸酯封端的预聚物的反应产物。
6.如权利要求1所述的热界面材料组合物，其中，所述硅烷封端的尿烷预聚物具有范围为约200-5000的分子量。
7.如权利要求6所述的热界面材料组合物，其中，所述硅烷封端的尿烷预聚物具有范围为约300-3000的分子量。
8.如权利要求7所述的热界面材料组合物，其中，所述硅烷封端的尿烷预聚物具有范围为约500-2000的分子量。
9.一种制品，其包含如权利要求1所述的热界面材料组合物。
10.如权利要求9所述的制品，其进一步包括由一个或多个电池单元、和冷却单元形成的电池模块，其中，所述电池模块通过所述热界面材料组合物连接至所述冷却单元。
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