JP2010179558A - Thermally conductive molded product and method of producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a thermally conductive molded product and a method of producing the same capable of producing a low-cost material which has a high thermal conductivity equal to or more than that of metal with a simple composition and, moreover, is light-weight like an organic synthetic resin. <P>SOLUTION: The method for producing the thermally conductive molded product 1A comprises: a cutting process (a) of cutting carbon fibers into short fibers 2A of a prescribed length; an alignment process (b) of aligning the short fibers 2A in a press mold 10; an inflow process (c) of causing a liquid epoxy resin 3A to flow into the press mold 10 in which the short fibers 2A are aligned; a press process (d) of pressing the liquid epoxy resin 3A as well as the aligned short fibers 2A in a direction vertical to the direction where the short fibers 2A are aligned by press molds 10, 12, the liquid epoxy resin 3A being infiltrated among the short fibers and into the short fibers as bundles of monofilaments and compressed to reduce the volume occupied by the liquid epoxy resin 3A to the irreducible minimum; and a curing process (e) of curing the liquid epoxy resin 3A, thereby imparting the surface hardness and strength to the whole of the molded product. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a thermally conductive molded article having a high thermal conductivity equal to or higher than that of a metal and being as light as an organic synthetic resin, and a method for producing the same. In the present specification, claims, drawings and abstract, the term “fiber” means a fiber composed of a bundle of single fibers except for the term “single fiber”. To do.

  In recent years, there has been remarkable progress in miniaturization and weight reduction in the field of electronic devices such as notebook personal computers, mobile phones, and digital cameras. On the other hand, the speed of semiconductor devices such as central processing units (CPUs) has also been dramatically increased. As a result, the amount of heat generated by semiconductor elements and the like has been steadily increasing. For this reason, there is a need for means for more efficiently releasing the heat generated in the electronic device without obstructing the demand for miniaturization and weight reduction.

  For this purpose, it is as light as an organic synthetic resin instead of a metal having high thermal conductivity such as copper (Cu) or aluminum (Al), which has been used as a heat radiator, and copper (Cu) or aluminum. It is necessary to manufacture a material having a thermal conductivity equal to or higher than that of a metal such as (Al).

  Therefore, in order to meet such a requirement, Patent Document 1 includes carbon fibers aligned in one direction in a polymer matrix material, and further includes a thermally conductive filler in the polymer matrix material. An invention of a high thermal conductivity material is disclosed. As a result, it is possible to provide a low-cost thermal conductive member that is as light as a polymer resin while having a high thermal conductivity equivalent to that of a metal.

Japanese Patent Laid-Open No. 2005-213459

  However, in the technique described in Patent Document 1, as shown in the examples, carbon fibers impregnated with an epoxy resin as a polymer matrix material are heated while isotropically applying pressure in an autoclave. Because it is cured, the volume content of carbon fiber is low, and those that do not contain aluminum oxide powder as a thermally conductive filler are insufficient in thermal conductivity and do not use a thermally conductive filler There is a problem that it is difficult to manufacture a material having a high composition and a high thermal conductivity.

  Therefore, the present invention has been made to solve such a problem, and can produce a material having a high thermal conductivity with a simple composition, and has a high thermal conductivity equal to or higher than that of a metal. However, it is an object of the present invention to provide a heat conductive molded body that is as light as an organic synthetic resin and at a low cost, and a method for producing the same.

  The thermally conductive molded article according to the invention of claim 1 is a thermally conductive molded article comprising a thermally conductive fiber and an organic synthetic resin, wherein the thermally conductive fibers are aligned in the same direction, and the gap is formed. The organic synthetic resin is filled and compressed in a direction perpendicular to the same direction.

  Here, as the “thermal conductive fiber”, carbon fiber (especially, coal pitch-based carbon fiber is preferable), metal fiber (especially copper fiber is preferable), and synthetic fiber are coated with a high thermal conductive material such as carbon or metal. Can be used. “Organic synthetic resins” include polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, acrylic resins, polytetrafluoroethylene, polyamide resins (especially nylon resins, especially hot melt nylons). Resin is preferable because of its high fluidity.), Thermoplastic resins such as aramid resin and ABS resin, phenol resin, epoxy resin, melamine resin, urea resin, unsaturated polyester resin, alkyd resin, polyurethane, thermosetting polyimide, etc. These thermosetting resins can be used.

  The heat conductive molded body according to the invention of claim 2 is the structure of claim 1, wherein the volume content of the heat conductive fiber is in the range of 64% to 90%, more preferably in the range of 65% to 75%. It is what is inside.

  According to a third aspect of the present invention, in the thermally conductive molded article according to the first or second aspect, the thermal conductive fiber has a thermal conductivity of 140 W / (m · K) to 900 W / (m · K). ), More preferably 500 W / (m · K) to 800 W / (m · K).

  According to a fourth aspect of the present invention, there is provided a thermally conductive molded article according to any one of the first to third aspects, further comprising natural fibers, inorganic fibers or organic fibers as a reinforcing material. Here, the natural fiber includes cotton yarn, hemp, silk, etc., the inorganic fiber includes glass fiber, and the like, and various synthetic fibers can be used as the organic fiber.

  According to a fifth aspect of the present invention, in the heat conductive molded body according to any one of the first to fourth aspects, a heat conductive sheet is further attached to the front and back surfaces perpendicular to the same direction. Is. Here, as a heat conductive sheet, copper foil, aluminum foil, stainless steel foil, etc. can be used, for example. Moreover, as an adhesive for affixing a heat conductive sheet, it is preferable to use heat conductive adhesives, such as a silver paste.

  The manufacturing method of the heat conductive molded object which concerns on invention of Claim 6 is a manufacturing method of the heat conductive molded object which consists of heat conductive fiber and organic synthetic resin, Comprising: The said heat conductive fiber is predetermined length. A short fiber obtaining step of obtaining the thermally conductive fibers cut into short fibers or preliminarily cut into short fibers, an aligning step of aligning the short fibers in a press mold, and the organic synthetic resin Inflowing into the press mold in a fluidized state, pressing the organic synthetic resin together with the aligned short fibers in the direction perpendicular to the aligned direction by the press mold, and the organic synthesis And a curing step for curing the resin.

  The manufacturing method of the heat conductive molded object which concerns on invention of Claim 7 is a manufacturing method of the heat conductive molded object which consists of a heat conductive fiber and organic synthetic resin, Comprising: The said organic synthetic resin is added to the said heat conductive fiber. An impregnation step for impregnating the organic synthetic resin in a fluid state, a semi-curing step for semi-curing the organic synthetic resin to a semi-fluid state, and a semi-cured short fiber having a predetermined length of heat conductive fibers impregnated with the semi-cured organic synthetic resin A cutting step of cutting the semi-cured short fibers into a press mold, and an alignment direction of the organic synthetic resin semi-cured by the press mold together with the aligned semi-cured short fibers. A pressing step for pressing in a vertical direction and a curing step for curing the semi-cured organic synthetic resin.

  The manufacturing method of the heat conductive molded object which concerns on invention of Claim 8 is a manufacturing method of the heat conductive molded object which consists of a heat conductive fiber and a thermoplastic resin, Comprising: The said thermoplastic resin is added to the said heat conductive fiber. An impregnation step in which the thermoplastic resin is impregnated in a fluid state, a solidification step in which the thermoplastic resin is cooled and solidified once, and a thermally conductive fiber impregnated with the solidified thermoplastic resin is cut into solid short fibers having a predetermined length A cutting step, an alignment step for aligning the solidified short fibers in a press mold, and a remelting step for heating the press mold to remelt the thermoplastic resin into a molten state or resoften into a semi-fluid state. A re-softening step, a pressing step in which the thermoplastic resin remelted or re-softened by the press mold is pressed together with the short fibers in a direction perpendicular to the aligned direction, and the thermoplastic resin is completely cooled and solidified again. The It is intended to and a resolidification process that.

  According to a ninth aspect of the present invention, there is provided a method for producing a thermally conductive molded body according to any one of the sixth to eighth aspects, wherein in the pressing step, pressing is performed and excess organic synthetic resin or excessive semi-curing is performed. The discharged organic synthetic resin is discharged from the press mold.

  A method for producing a thermally conductive molded article according to the invention of claim 10 is a method for producing a thermally conductive molded article comprising a thermally conductive fiber and an organic synthetic resin, wherein the thermally conductive fibers are aligned while being bundled. An alignment step of passing through the mold, and an extrusion step of extruding the organic synthetic resin in a fluidized state while flowing into the mold simultaneously with the alignment step, and impregnating the thermally conductive fibers, and the organic A curing step of curing the synthetic resin, and a cutting step of cutting the extruded molded body in a direction perpendicular to the aligned direction.

  The method for producing a thermally conductive molded body according to the invention of claim 11 is the structure according to any one of claims 6 to 10, wherein the thermally conductive fiber has a thermal conductivity of 140 W / (m · K). The carbon fiber is within a range of ˜900 W / (m · K), more preferably within a range of 500 W / (m · K) to 800 W / (m · K).

  The manufacturing method of the heat conductive molded object which concerns on invention of Claim 12 WHEREIN: In any one structure of Claim 6 thru | or 11, in addition to the said heat conductive fiber and the said organic synthetic resin, it is further as a reinforcing material. It contains natural fiber, inorganic fiber or organic fiber. Here, the natural fiber includes cotton yarn, hemp, silk, etc., the inorganic fiber includes glass fiber, and the like, and various synthetic fibers can be used as the organic fiber.

  The method of manufacturing a thermally conductive molded body according to the invention of claim 13 is the structure according to any one of claims 6 to 12, wherein after the curing step, a surface and a back surface perpendicular to the aligned direction are further provided. A flat polishing step for performing flat polishing and a pasting step in which a thermally conductive sheet is bonded to the surface and the back surface which have been flat polished, respectively.

  Here, as a heat conductive sheet, copper foil, aluminum foil, stainless steel foil, etc. can be used, for example. Moreover, as an adhesive for affixing a heat conductive sheet, it is preferable to use heat conductive adhesives, such as a silver paste.

  Since the heat conductive molded body according to the invention of claim 1 is a heat conductive molded body made of a heat conductive fiber and an organic synthetic resin, the composition is simple, the manufacture is easy, and the cost can be reduced. it can. In addition, since the thermally conductive fibers are aligned in the same direction and the gap is filled with organic synthetic resin, high thermal conductivity equivalent to that of metal is obtained in the direction in which the thermally conductive fibers are aligned. Can be both light and light. And since it compresses in the direction perpendicular | vertical with respect to the same direction, the volume content rate of a heat conductive fiber becomes high, and high heat conductivity can be ensured only with a heat conductive fiber and organic synthetic resin. .

  In this way, it is possible to produce a material having a simple composition and high thermal conductivity, and having a thermal conductivity equivalent to or higher than that of a metal, it is as light as an organic synthetic resin, and has a low cost. It becomes.

  In the heat conductive molded body according to the invention of claim 2, since the volume content of the heat conductive fiber is in the range of 64% to 90%, in addition to the effect of the invention according to claim 1, it is ensured. In addition, it has a high thermal conductivity equivalent to or higher than that of metal, and contains a certain volume or more of organic synthetic resin, so that strength and lightness can be ensured. In particular, when the volume content of the heat conductive fiber is in the range of 65% to 75%, the heat conductivity is more reliably maintained as high as that of the metal, and has strength and lightness. Therefore, it is more preferable.

  In the heat conductive molded object which concerns on invention of Claim 3, a heat conductive fiber is a carbon fiber in the range whose heat conductivity is 140 W / (m * K)-900 W / (m * K). In addition to the effects of the invention according to claim 1 or 2, even if the volume content of the heat conductive fiber is high, the strength and lightness equivalent to those of the organic synthetic resin can be maintained.

  Here, when the thermal conductivity of the carbon fiber as the thermal conductive fiber is less than 140 W / (m · K), it becomes difficult to ensure a high thermal conductivity equal to or higher than that of the metal, Since those having a thermal conductivity exceeding 900 W / (m · K) are expensive, the thermal conductivity of the carbon fiber may be in the range of 140 W / (m · K) to 900 W / (m · K). preferable. In particular, when the thermal conductivity of the carbon fiber is in the range of 500 W / (m · K) to 800 W / (m · K), it becomes easier to secure low cost and high thermal conductivity. preferable.

  In the heat conductive molded body according to the invention of claim 4, since it contains not only the heat conductive fibers but also natural fibers, inorganic fibers or organic fibers as reinforcing materials, the heat conductive fibers and the natural fibers, By adjusting the mixing ratio with the inorganic fiber or the organic fiber, it is possible to easily produce a thermally conductive molded article having a desired thermal conductivity and to reduce the amount of the thermally conductive fiber used. Therefore, a thermally conductive molded object can be manufactured at lower cost.

  In the thermally conductive molded body according to the invention of claim 5, since the thermally conductive sheet is further attached to the front and back surfaces perpendicular to the longitudinal direction of the thermally conductive fibers, the heat of the thermally conductive molded body Without reducing the conductivity, the strength of the surface direction of the thermally conductive molded body (the direction in which the thermally conductive fibers are separated) can be improved, and the thickness of the thermally conductive molded body. Directional cracks can be prevented. Here, the use of a heat conductive adhesive such as a silver paste as an adhesive for attaching the heat conductive sheet is more preferable because a decrease in heat conductivity is more reliably prevented.

  In the manufacturing method of the heat conductive molded object which concerns on invention of Claim 6, a heat conductive fiber is first cut | disconnected by the short fiber of predetermined length in the short fiber acquisition process, or is previously cut | disconnected by the short fiber of predetermined length. In the aligning process, these short fibers are aligned in the press mold, and in the inflow process, the organic synthetic resin is flowed into the press mold in which the short fibers are aligned. In the pressing step, the organic synthetic resin is pressed in a direction perpendicular to the aligned direction together with the short fibers aligned by the press mold.

  As a result, the organic synthetic resin enters between the arranged short fibers and the short fibers which are bundles of single fibers, and the volume occupied by the organic synthetic resin is minimized by being compressed. Thereafter, by curing the organic synthetic resin in the curing step (that is, in the case of a thermoplastic resin, it is cooled to a melting point or a glass transition point or lower, and in the case of a thermosetting resin, it is heated to a curing temperature or higher). Surface hardness and strength are imparted to the whole to obtain a thermally conductive molded body.

  Thus, since the manufacturing method of the heat conductive molded object which concerns on this invention uses only a heat conductive fiber and an organic synthetic resin as a raw material, a composition is simple, manufacture is also easy and can be reduced in cost. . In addition, since the thermally conductive fibers are aligned in the same direction and the gap is filled with organic synthetic resin, high thermal conductivity equivalent to that of metal is obtained in the direction in which the thermally conductive fibers are aligned. Can be both light and light. And since it compresses in the direction perpendicular | vertical with respect to the same direction, the volume content rate of a heat conductive fiber becomes high, and high heat conductivity can be ensured only with a heat conductive fiber and organic synthetic resin. .

  In this way, it is possible to produce a material having a simple composition and high thermal conductivity, and having a thermal conductivity equivalent to or higher than that of a metal, it is as light as an organic synthetic resin, and has a low cost. The manufacturing method becomes.

  In the manufacturing method of the heat conductive molded object which concerns on invention of Claim 7, first, an organic synthetic resin is impregnated in the fluid state in the heat conductive fiber in the impregnation process, and the impregnated organic synthetic resin is semi-fluidized in the semi-curing process. Semi-cured to state. Then, since the heat conductive fibers impregnated with the semi-cured organic synthetic resin in the cutting step are cut into semi-cured short fibers of a predetermined length, even if the heat conductive fibers as a raw material are brittle, sufficient Strength is obtained and handling becomes easy. Therefore, an alignment process for aligning the semi-cured short fibers in the press mold can be easily performed.

  Then, in the pressing step, the semi-cured short fibers aligned in the press mold are pressed in a direction perpendicular to the direction aligned by the press mold, and the short fibers that are bundles of single fibers are arranged between the aligned short fibers. As the organic synthetic resin further enters, it is compressed and the volume occupied by the organic synthetic resin is minimized. Thereafter, by curing the organic synthetic resin in the curing step (that is, in the case of a thermoplastic resin, it is cooled to a melting point or a glass transition point or lower, and in the case of a thermosetting resin, it is heated to a curing temperature or higher). Surface hardness and strength are imparted to the whole to obtain a thermally conductive molded body.

  Thus, since the manufacturing method of the heat conductive molded object which concerns on this invention uses only a heat conductive fiber and an organic synthetic resin as a raw material, a composition is simple, manufacture is also easy and can be reduced in cost. . In addition, since the thermally conductive fibers are aligned in the same direction and the gap is filled with organic synthetic resin, high thermal conductivity equivalent to that of metal is obtained in the direction in which the thermally conductive fibers are aligned. Can be both light and light. And since it compresses in the direction perpendicular | vertical with respect to the same direction, the volume content rate of a heat conductive fiber becomes high, and high heat conductivity can be ensured only with a heat conductive fiber and organic synthetic resin. .

  The method for producing a thermally conductive molded body according to the invention of claim 8 is a method in which a thermoplastic resin is cooled and solidified, then cut into solidified short fibers, and the solidified short fibers are aligned in a press mold. Therefore, when the impregnated thermoplastic resin is solidified, it is stronger, easier to handle, and less likely to break, so it is easier to automate each process with a cutting device or an alignment robot, resulting in defective products It becomes a mass production method with a low rate.

  In the manufacturing method of the heat conductive molded object which concerns on invention of Claim 9, it presses and discharges an excess organic synthetic resin or an extra semi-hardened organic synthetic resin from a press die in a press process. In addition to the effect of the invention according to any one of claims 6 to 8, the volume content of the heat conductive fiber is further increased, and the volume content of the organic synthetic resin is more reliably suppressed to the necessary minimum. Thus, high thermal conductivity can be ensured only with the heat conductive fiber and the organic synthetic resin.

  In the method for manufacturing a thermally conductive molded body according to the invention of claim 10, the thermally conductive fibers are aligned while being bundled and passed through the mold, and at the same time, the organic synthetic resin is allowed to flow into the mold in a fluidized state. Since it is a manufacturing method in which extrusion molding is performed while impregnating the conductive fiber and the extruded product is cut, it is a mass production method capable of continuous manufacturing, and thus heat having both high thermal conductivity and light weight. The conductive molded body can be manufactured at a much lower cost.

  In the manufacturing method of the heat conductive molded object which concerns on invention of Claim 11, a heat conductive fiber is a carbon fiber in the range whose heat conductivity is 140 W / (m * K)-900 W / (m * K). Therefore, in addition to the effects of the invention according to any one of claims 6 to 10, the strength and lightness equivalent to those of the organic synthetic resin are maintained even if the volume content of the heat conductive fiber is high. be able to.

  Here, when the thermal conductivity of the carbon fiber as the thermal conductive fiber is less than 140 W / (m · K), it becomes difficult to ensure a high thermal conductivity equal to or higher than that of the metal, Since those having a thermal conductivity exceeding 900 W / (m · K) are expensive, the thermal conductivity of the carbon fiber may be in the range of 140 W / (m · K) to 900 W / (m · K). preferable. In particular, when the thermal conductivity of the carbon fiber is in the range of 500 W / (m · K) to 800 W / (m · K), it becomes easier to secure low cost and high thermal conductivity. preferable.

  In the manufacturing method of the heat conductive molded object which concerns on invention of Claim 12, in addition to a heat conductive fiber and organic synthetic resin, since natural fiber, inorganic fiber, or organic fiber as a reinforcing material is contained, heat conduction is carried out. By adjusting the mixing ratio of the conductive fiber and natural fiber, inorganic fiber or organic fiber, it is possible to easily produce a thermally conductive molded article having the desired thermal conductivity, and to use the thermally conductive fiber. Since the amount can be reduced, the thermally conductive molded body can be produced at a lower cost.

  In the manufacturing method of the heat conductive molded object which concerns on invention of Claim 13, the surface grinding | polishing process which planarly polishes the surface and back surface perpendicular | vertical to the aligned direction after a hardening process, and the surface and back surface by which surface grinding | polishing was carried out is carried out. Each of which has a bonding step for bonding a heat conductive sheet, and the surface direction of the heat conductive molded body in which the structural strength tends to be small due to the bonding of the heat conductive sheet (between the heat conductive fibers). The strength in the direction in which the thermal conductive molded body is separated) can be improved, and cracking in the thickness direction of the thermally conductive molded body can be prevented without reducing the thermal conductivity of the thermally conductive molded body.

  Here, by using a heat conductive adhesive such as a silver paste as an adhesive for attaching the heat conductive sheet in the attaching step, a decrease in the heat conductivity of the heat conductive molded body is more reliably prevented. Therefore, it is more preferable.

FIG. 1 is a perspective view schematically showing an overall configuration of a thermally conductive molded body according to Embodiment 1 of the present invention. 2 (a), (b), (c), (d), (e), and (f) are schematic views showing a method for manufacturing a thermally conductive molded body according to Embodiment 1 of the present invention. 3 (a) and 3 (b) are schematic diagrams showing a method for measuring the thermal conductivity of the thermally conductive molded body according to Embodiment 1 of the present invention. 4 (a), (b), (c), (d), (e), (f), and (g) are schematic diagrams showing a method for manufacturing a thermally conductive molded body according to Embodiment 2 of the present invention. FIG. FIG. 5 is a diagram showing the relationship between the estimated value and the measured value of the thermal conductivity of the thermally conductive molded body according to Embodiment 1 and Embodiment 2 of the present invention. 6 (a), (b), (c), and (d) are schematic views showing a method for manufacturing a thermally conductive molded body according to Embodiment 3 of the present invention. 7A, 7B, 7C and 7D are schematic views showing a method for manufacturing a thermally conductive molded body according to a modification of Embodiment 3 of the present invention. 8 (a) and 8 (b) are schematic diagrams showing a method for manufacturing a thermally conductive molded body according to Embodiment 4 of the present invention. 9 (a), (b), (c), and (d) are schematic views showing a method for manufacturing a thermally conductive molded body according to a first modification of Embodiment 4 of the present invention. 10 (a), (b), (c), (d), (e), and (f) show a method for manufacturing a thermally conductive molded body according to a second modification of Embodiment 4 of the present invention. It is a schematic diagram.

  Embodiments of a thermally conductive molded body and a method for producing the same according to the present invention will be described below with reference to the drawings.

Embodiment 1
First, Embodiment 1 of the heat conductive molded object which concerns on this invention, and its manufacturing method is demonstrated with reference to FIG. 1 thru | or FIG. FIG. 1 is a perspective view schematically showing an overall configuration of a thermally conductive molded body according to Embodiment 1 of the present invention. 2 (a), (b), (c), (d), (e), and (f) are schematic views showing a method for manufacturing a thermally conductive molded body according to Embodiment 1 of the present invention. 3 (a) and 3 (b) are schematic diagrams showing a method for measuring the thermal conductivity of the thermally conductive molded body according to Embodiment 1 of the present invention.

  As shown in FIG. 1, the thermally conductive molded body 1 according to the first embodiment includes a thermally conductive fiber 2 and an organic synthetic resin 3, and the thermally conductive fibers 2 are aligned in the same direction, The gap is filled with the organic synthetic resin 3. As indicated by arrows in FIG. 1, the heat conductive fibers 2 are compressed in a direction (A direction and / or B direction) perpendicular to the aligned direction. As a result, the organic synthetic resin 3 is compressed and the volume occupied by the organic synthetic resin 3 is minimized, and the thermal conductivity of the thermally conductive fibers 2 is almost the same as the high thermal conductivity in the aligned direction of the thermally conductive fibers 2. It becomes the heat conductive molded object 1 which has high heat conductivity.

  Next, the specific manufacturing method of such a heat conductive molded object 1 is demonstrated with reference to FIG. In Embodiment 1, coal pitch carbon fiber 2A is used as heat conductive fiber 2, and more specifically, coal manufactured by Mitsubishi Plastics (Mitsubishi Chemical Industrial Co., Ltd.). Pitch-based carbon fiber K63312 (having a thermal conductivity of 515 W / (m · K)) and coal pitch-based carbon fiber K223HG (having a thermal conductivity of 140 W) manufactured by Mitsubishi Plastics (Mitsubishi Chemical Corporation) / (M · K)). Further, as the organic synthetic resin 3, a liquid epoxy resin 3A which is a thermosetting resin is used, and more specifically, an Epofix (two-component liquid epoxy cold embedding resin) manufactured by Struers is used. ing.

  First, as shown in FIG. 2 (a), in the cutting step, the carbon fibers are cut into short fibers 2A having a predetermined length, and as shown in FIG. 2 (b), the short fibers 2A are cut in the alignment step. The press mold 10 is filled in a state aligned in the same direction (direction perpendicular to the paper surface in FIG. 2B). Next, as shown in FIG. 2C, in the inflow process, the liquid epoxy resin 3A is poured together with the curing agent into the press mold 10 in which the short fibers 2A are aligned.

  Subsequently, as shown in FIG. 2D, in the pressing process, the liquid epoxy resin 3A is pressed together with the short fibers 2A aligned by the press dies 10 and 12 in a direction perpendicular to the aligned direction. As a result, the liquid epoxy resin 3A enters between the short fibers 2A and the short fibers 2A that are bundles of single fibers, and the excess liquid epoxy resin 3A is compressed while being squeezed out of the press mold 10, The volume occupied by the liquid epoxy resin 3A is the minimum necessary.

  Here, as shown in FIG. 2 (d), as Example 1 of the method for manufacturing a thermally conductive molded body according to the first embodiment, a pitch system having a thermal conductivity of 515 W / (m · K). The carbon fiber was compressed from an initial height of 28 mm before pressing to a height of 15 mm after pressing. Further, as Example 2, a pitch-based carbon fiber having a thermal conductivity of 140 W / (m · K) was used to compress from an initial height of 28 mm before pressing to a height of 14 mm after pressing.

  Thereafter, as shown in FIG. 2 (e), in the curing step, the liquid epoxy resin 3A to which the curing agent is added in advance is cured by being held in a pressed state at room temperature for 8 hours or more, and the whole is cured. Surface hardness and strength are imparted, and as shown in FIG. 2 (f), a heat conductive molded body 1 </ b> A composed of the carbon fibers 2 </ b> A and the epoxy resin 3 </ b> A is obtained.

  The thermal conductivity of the heat conductive molded body 1A (Examples 1 and 2) according to the first embodiment manufactured as described above was measured by a laser flash method (JIS-R1611). For comparison, as Comparative Example 1, a pitch-based carbon fiber having a thermal conductivity of 515 W / (m · K) as in Example 1 was used, and the thermal conductivity was not performed. A molded body was produced, and the thermal conductivity was similarly measured by a laser flash method.

  An outline of thermal conductivity measurement by the laser flash method will be described with reference to FIG. As shown in FIG. 3A, in the laser flash method, the surface of a disk-shaped sample (10 mmφ, thickness 2 mm) is irradiated with laser light from a laser light source, and the temperature of the back surface of the sample is measured with a thermocouple. To do.

  As a result, as shown in FIG. 3B, the specific heat Cp of the sample is obtained from the amount of heat applied to the surface of the sample, the temperature rise of the back surface of the sample, and the weight of the sample. The thermal diffusivity α of the sample is determined from the time until the sample is transmitted and the thickness of the sample. From these specific heat Cp and thermal diffusivity α and the density ρ of the sample measured separately, λ = α · Cp · ρ The thermal conductivity λ of the sample is calculated by the relational expression.

  A disk-shaped sample (10 mmφ, 2 mm in thickness) is cut out from the thermally conductive molded body 1A shown in FIG. 2 (f) so that the thickness direction is aligned with the carbon fibers 2A, and laser flash method is performed. Was used to measure the thermal conductivity. As a measuring device by the laser flash method, a thermophysical property measuring device LFA-502 manufactured by Kyoto Electronics Industry Co., Ltd. was used. As a result, the thermal conductivity of the thermally conductive molded body according to Example 1 of the first embodiment is 361.3 W / (m · K), and the thermal conductivity of the thermally conductive molded body according to Example 2. Was 109.7 W / (m · K). These measurement results are summarized in Table 1.

As shown in Table 1, the heat conductive molded body 1A of Example 1 using pitch-based carbon fibers (CF) having a thermal conductivity of 515 W / (m · K) has a resin density of an epoxy resin. 1.15 g / cm ^3, since the density of the carbon fiber (CF) is 2.20 g / cm ^3, a bulk density of the entire heat conductive body 1A is 1.87 g / cm ^3, the volume content of carbon fibers Is 68.6%. The heat conductive molded body 1A of Example 1 has a heat conductivity at 24 ° C. of specific heat × thermal diffusivity × density = 855 × 0.000226 × 1870 = 361.3 W / (m · K) The rate of decrease in thermal conductivity compared to the carbon fiber of 70.2% was 70.2%.

Further, in the heat conductive molded body 1A of Example 2 using pitch-based carbon fibers (CF) having a thermal conductivity of 140 W / (m · K), the resin density of the epoxy resin is 1.15 g / cm ^3. , since the density of the carbon fiber (CF) is 2.12 g / cm ^3, a bulk density of the entire heat conductive body 1A is 1.78 g / cm ^3, the volume content of the carbon fibers and 64.9% Become. The heat conductive molded body 1A of Example 2 has a thermal conductivity at 24 ° C. of specific heat × thermal diffusivity × density = 781 × 0.0000789 × 1780 = 19.7 W / (m · K), The rate of decrease in thermal conductivity compared to carbon fiber was 78.3%.

On the other hand, as shown in Table 1, pitch-based carbon fibers having a thermal conductivity of 515 W / (m · K) were used, but they were manufactured without performing a pressing step (compression). molded article of Comparative example 1, the resin density of 1.15 g / cm ³ of the epoxy resin, the density of the carbon fiber (CF) is 2.20 g / cm ^3, the bulk density of the entire molded product in 1.56 g / cm ³ Therefore, the volume content of carbon fiber is 39.0%.

  Thus, as shown in Table 1, the molded body of Comparative Example 1 having a low carbon fiber volume content compared to Example 1 and Example 2 has a specific heat and density in the measurement by the laser flash method. Although it was possible to determine the thermal diffusivity because the laser beam passed through the epoxy resin portion, it was not possible to determine the thermal conductivity.

As described above, the thermal conductive molded bodies 1A according to Example 1 and Example 2 of the first embodiment have thermal conductivities of 361.3 W / (m · K) and 109.7 W / (m, respectively. K) is as high as metal, and the carbon fiber volume content is as high as 68.6% and 64.9%, respectively, while the bulk density is 1.87 g / cm ³ and 1.78 g / cm ³ , respectively, organic It was as small as a synthetic resin.

  In this way, in the heat conductive molded body 1A according to the first embodiment and the manufacturing method thereof, a material having a simple composition and high thermal conductivity can be manufactured, and the heat is equal to or higher than that of metal. It is possible to obtain a heat conductive molded body 1A having low conductivity and being as light as an organic synthetic resin and having a low cost.

Embodiment 2
Next, Embodiment 2 of the thermally conductive molded body and the manufacturing method thereof according to the present invention will be described with reference to FIGS. 4 (a), (b), (c), (d), (e), (f), and (g) are schematic diagrams showing a method for manufacturing a thermally conductive molded body according to Embodiment 2 of the present invention. FIG. FIG. 5 is a diagram showing the relationship between the estimated value and the measured value of the thermal conductivity of the thermally conductive molded body according to Embodiment 1 and Embodiment 2 of the present invention.

  A specific method for manufacturing the thermally conductive molded body according to the second embodiment will be described with reference to FIG. In the second embodiment, coal pitch carbon fiber 2Ba is used as the heat conductive fiber 2, and more specifically, coal manufactured by Mitsubishi Plastics (Mitsubishi Chemical Industrial Co., Ltd.). Pitch-based carbon fiber K13D2U (with a thermal conductivity of 770 W / (m · K) higher than that of the first embodiment) is used. Further, as the organic synthetic resin 3, a phenol resin 3B which is a thermosetting resin is used.

  First, as shown in FIG. 4A, in the impregnation step, the carbon fiber 2Ba is immersed in a liquid phenol resin 3B placed in a container, and impregnation with the phenol resin 3B is performed. Subsequently, as shown in FIG. 4B, in the semi-curing step, the carbon fiber 2Ba impregnated with the phenol resin 3B is heated at 80 ° C. for 15 minutes, and the phenol resin 3B is semi-cured into a semi-fluid state. The cured carbon fiber 2Bb is used.

  Next, as shown in FIG. 4 (c), in the cutting step, the semi-cured carbon fiber 2Bb is cut into semi-cured short fibers 2Bc having a predetermined length (10 mm), as shown in FIG. 4 (d). In the alignment step, the semi-cured short fibers 2Bc are filled in the press mold 10 in an aligned state in the same direction (a direction perpendicular to the paper surface in FIG. 4D). Then, as shown in FIG. 4E, in the pressing process, the press molds 10 and 12 press the semi-cured phenolic resin 3B along with the semi-cured short fibers 2Bc aligned in the direction perpendicular to the aligned direction. Is done.

  As a result, the semi-cured phenol resin 3B is compressed while being squeezed out of the press mold 10, and the volume occupied by the semi-cured phenol resin 3B is minimized. Here, as shown in FIG. 4 (e), as Example 3 of the method for manufacturing a thermally conductive molded body according to the second embodiment, a pitch system having a thermal conductivity of 770 W / (m · K) is used. The carbon fiber was compressed from an initial height of 28 mm before pressing to a height of 14 mm after pressing.

  Thereafter, as shown in FIG. 4 (f), in the curing step, the semi-cured phenol resin 3B is completely cured by being heated in a pressed state at 150 ° C. for 30 minutes, so that the entire surface hardness and strength are obtained. As shown in FIG. 4G, a thermally conductive molded body 1B made of carbon fiber 2B and phenol resin 3B is obtained.

  The reason why such a manufacturing method is adopted is that the pitch-based carbon fiber 2Ba having a high thermal conductivity of 770 W / (m · K) has a thermal conductivity of 515 W / (m · K) according to the first embodiment. 2 and 140 W / (m · K) pitch-based carbon fiber 2A, it is fragile. Therefore, when the manufacturing method as shown in FIG. The carbon fiber collapses when it is filled. Therefore, as shown in FIG. 4, the resin is impregnated in advance and semi-cured, and then cut and filled into a press die.

  As in the case of the first embodiment, the thermal conductivity of the heat conductive molded body 1B according to the second embodiment manufactured in this way (Example 3) is measured by the laser flash method (JIS-R1611). It was measured. That is, a disk-shaped sample (10 mmφ, thickness 2 mm) is cut out from the thermally conductive molded body 1B shown in FIG. 4 (g) so that the thickness direction is aligned with the carbon fibers 2B. The thermal conductivity was measured by the flash method. As a measuring device by the laser flash method, a thermophysical property measuring device LFA-502 manufactured by Kyoto Electronics Industry Co., Ltd. was used. As a result, the thermal conductivity of the thermally conductive molded body according to Example 3 of Embodiment 2 was 217.8 W / (m · K). Table 2 shows the production method, physical property data, and measurement results.

As shown in Table 2, the thermally conductive molded body 1B of Example 3 using pitch-based carbon fibers (CF) having a thermal conductivity of 770 W / (m · K) has a resin density of phenol resin. 1.26 g / cm ^3, since the density of the carbon fiber (CF) is 2.21 g / cm ^3, a bulk density of the entire heat conductive body 1B is 1.66 g / cm ^3, the volume content of carbon fibers Is 42.1%. The heat conductive molded body 1B of Example 2 has a heat conductivity at 24 ° C. of specific heat × thermal diffusivity × density = 805 × 0.000163 × 1660 = 27.1W / (m · K) The decrease rate of the thermal conductivity compared with the carbon fiber of 28.3% was 28.3%.

Thus, although the heat conductive molded object 1B of Example 3 is low in volume content of carbon fiber compared with Example 1 and Example 2, and the fall rate of thermal conductivity is also large, the pitch which is a raw material is -Based carbon fiber 2Ba has a high thermal conductivity of 770 W / (m · K), and thus exhibits a high thermal conductivity of 217.8 W / (m · K), equivalent to or higher than that of metal, while the bulk density is 1.66 g. / Cm ^3, which is as small as an organic synthetic resin.

  Thus, in the heat conductive molded object 1B and the manufacturing method thereof according to the second embodiment, a material having a simple composition and high thermal conductivity can be manufactured, and the heat is equal to or higher than that of a metal. It is possible to obtain a low-cost thermally conductive molded body 1 </ b> B that is as light as an organic synthetic resin while having conductivity.

  FIG. 5 shows a diagram in which the thermal conductivity of the thermally conductive molded body according to the first embodiment and the second embodiment described above is plotted against the thermal conductivity of the carbon fiber that is the raw material. The symbol □ indicates an estimated value, and the symbol ■ indicates a measured value. The estimated value is calculated by multiplying the volume content (of carbon fiber) shown in Tables 1 and 2 by the thermal conductivity of the original carbon fiber.

  As shown in FIG. 5, with respect to Example 1 and Example 2 according to the first embodiment, the estimated values and the measured values are quite in agreement, but with respect to Example 3 according to the second embodiment. The measured value is much smaller than the estimated value. Therefore, it is thought that by elucidating the cause, it is possible to further improve the thermal conductivity of the thermal conductive molded body 1B obtained by the manufacturing method according to the second embodiment.

Embodiment 3
Next, Embodiment 3 of the thermally conductive molded body and the manufacturing method thereof according to the present invention will be described with reference to FIGS. 6 (a), (b), (c), and (d) are schematic views showing a method for manufacturing a thermally conductive molded body according to Embodiment 3 of the present invention. 7A, 7B, 7C and 7D are schematic views showing a method for manufacturing a thermally conductive molded body according to a modification of Embodiment 3 of the present invention.

  The manufacturing method of the heat conductive molded object which concerns on this Embodiment 3 is demonstrated with reference to FIG. The manufacturing method of the heat conductive molded object which concerns on this Embodiment 3 (and its modification) improves the manufacturing method of the heat conductive molded object which concerns on the said Embodiment 2, and has a more mass-productive manufacturing method It is what. In the third embodiment, coal pitch-based carbon fiber 2Ca is used as the heat conductive fiber 2, and a phenol resin 3 </ b> C that is a thermosetting resin is used as the organic synthetic resin 3.

  As shown in FIG. 6 (a), in the pultrusion device 13, first, roving the coal pitch-based carbon fiber 2Ca (several tens of strands obtained by bundling 2000 to 12000 carbon fiber filaments (single fibers). Pulled out from 14C and threaded through liquid phenolic resin 3C filled in container 15 to impregnate carbon fiber 2Ca with phenolic resin 3C (impregnation step). Then, the carbon fiber 2Ca impregnated with the phenol resin 3C is introduced into the semi-curing furnace 17 while being wound by the roller 16, and heated to semi-cur the phenol resin 3C to form a semi-cured carbon fiber 2Cb (semi-cured) Process).

  Next, as shown in FIG. 6 (b), the semi-cured carbon fiber 2Cb is cut into a predetermined length by a cutting device (not shown) to obtain a semi-cured short fiber 2Cc (cutting step), and the obtained half-cured carbon fiber 2Cb is cut. The cured short fibers 2Cc are filled in the press mold 10 in the same direction by an unillustrated robot (alignment process). Then, as shown in FIG. 6C, the pressurizing mechanism 11 is operated to push the press mold 12 into the press mold 10, thereby semi-cured short fibers 2Cc in which the semi-cured phenol resins 3C are aligned. At the same time, the extra semi-cured phenol resin 3C is squeezed out from a through hole (not shown) while being pressed in a direction perpendicular to the aligned direction (pressing step).

  Then, by heating to a higher temperature in the state shown in FIG. 6C, the semi-cured phenol resin 3C is completely cured (curing step), and as shown in FIG. A thermally conductive molded body 1C according to the third embodiment, which includes carbon fiber 2C as a fiber and phenol resin 3C as an organic synthetic resin, is obtained. Thus, in the manufacturing method of the heat conductive molded object which concerns on this Embodiment 3 shown by FIG. 6, the roller 16, the semi-hardening furnace 17, the cutting device which is not shown, the robot which is not shown, and the pressurization mechanism 11 are provided. In addition, since the press molds 10 and 12 are used, it is possible to easily automate the manufacturing method of the heat conductive molded body having higher mass productivity. Therefore, further cost reduction can be realized.

  Next, the manufacturing method of the heat conductive molded object which concerns on the modification of this Embodiment 3 is demonstrated with reference to FIG. In the modification of the third embodiment, coal pitch-based carbon fibers 2Da are used as the heat conductive fibers 2, and a phenol resin 3D which is a thermosetting resin is used as the organic synthetic resin 3.

  As shown in FIG. 7A, first, in the pultrusion device 13, the coal pitch-based carbon fiber 2Da is pulled out from the roving 14D and passed through the liquid phenolic resin 3D filled in the container 15, The carbon fiber 2Da is impregnated with the phenol resin 3D (impregnation step). Then, the carbon fiber 2Da impregnated with the phenol resin 3D is introduced into the semi-curing furnace 17 while being wound by the roller 16, and heated to semi-cur the phenol resin 3D to form a semi-cured carbon fiber 2Db (semi-cured) Process).

  Subsequently, the semi-cured carbon fiber 2Db is cut into a predetermined length by a cutting device (not shown) to form a semi-cured short fiber 2Dc (cutting step), and the obtained half-cured fiber is obtained as shown in FIG. 7B. The cured short fibers 2Dc are sent by a robot (not shown) to a ribbon forming apparatus including the pressing member 18 and the semi-heated alignment member 19, and the semi-cured short fibers 2Dc are fused together to form a ribbon-like sheet 4, and the ribbon. The sheet 4 is wound up to form a sheet roll 5.

  As shown in FIG. 7C, by setting the sheet roll 5 in the press mold 20, the semi-cured short fibers 2Dc are filled in the press mold 20 in the same direction (alignment). Process). Then, as shown in FIG. 7 (c), the sheet roll 5 is pressed by a press die 20 (pressing step), and further heated at a higher temperature, whereby the semi-cured phenol resin 3B is completely cured. (Curing process), the surface hardness and strength are given to the whole, and as shown in FIG. 7 (d), the present is composed of carbon fiber 2D as a heat conductive fiber and phenol resin 3D as an organic synthetic resin. A hexagonal prism-shaped thermally conductive molded body 1D according to a modification of the third embodiment is obtained.

  Thus, in the manufacturing method of the heat conductive molded object which concerns on this Embodiment 3 shown by FIG. 7, the roller 16, the semi-hardening furnace 17, the cutting device which is not shown, the robot which is not shown, the pressurizing member 18, and the half Since the ribbon forming device including the heating alignment member 19 and the press die 20 are used, it is possible to easily automate the manufacturing method of the heat conductive molded body having higher mass productivity. Therefore, further cost reduction can be realized.

  Thus, in the heat conductive molded object and its manufacturing method which concern on this Embodiment 3, the raw material which has a simple composition and high heat conductivity can be manufactured, and high heat conductivity equivalent to or more than a metal It is possible to obtain low-cost thermally conductive molded articles 1C and 1D that are as light as organic synthetic resins while having a high rate.

Embodiment 4
Next, Embodiment 4 of the heat conductive molded object and its manufacturing method which concern on this invention is demonstrated with reference to FIG. 8 thru | or FIG. 8 (a) and 8 (b) are schematic diagrams showing a method for manufacturing a thermally conductive molded body according to Embodiment 4 of the present invention. 9 (a), (b), (c), and (d) are schematic views showing a method for manufacturing a thermally conductive molded body according to a first modification of Embodiment 4 of the present invention. 10 (a), (b), (c), (d), (e), and (f) show a method for manufacturing a thermally conductive molded body according to a second modification of Embodiment 4 of the present invention. It is a schematic diagram.

  The manufacturing method of the heat conductive molded object which concerns on this Embodiment 4 is demonstrated with reference to FIG. The method for producing a thermally conductive molded body according to the fourth embodiment (and the first and second modifications thereof) is characterized by using a thermoplastic resin as the organic synthetic resin and excellent in mass productivity. Manufacturing method.

  As shown in FIG. 8, in the method for manufacturing a thermally conductive molded body according to the fourth embodiment, coal pitch-based carbon fibers 2Ea are used as the thermally conductive fibers 2, and the organic synthetic resin 3 is used as the synthetic resin 3. A hot melt nylon resin 3E, which is a thermoplastic resin, is used.

  As shown in FIG. 8A, in the fourth embodiment, one coal pitch-based carbon fiber 2Ea is pulled out from each of a large number of rovings 14E, and a large number are bundled to form an extruder 21 at a time. The hot melt nylon resin 3E is introduced into the resin plasticizing cylinder 21a of the extrusion molding machine 21 from the hopper 21b and screwed in the resin plasticizing cylinder 21a of the extrusion molding machine 21 at the same time. Is melted by heating, extruded into the base body 21c, impregnated and integrated with the carbon fiber 2Ea, and extruded as a block-shaped extruded product 6.

  By cutting the extruded molded body 6 to a predetermined thickness with a cutting device in a state where the hot melt nylon resin 3E is still soft, or after the extruded molded body 6 is sufficiently cooled and the nylon resin 3E is cured. As shown in FIG. 8B, a rectangular parallelepiped thermally conductive molded body 1E according to the fourth embodiment, which is composed of carbon fibers 2E as thermally conductive fibers and nylon resin 3E as organic synthetic resin. Can be manufactured in large quantities in a short time.

  Thus, the manufacturing method of the heat conductive molded object which concerns on this Embodiment 4 is a mass production method in which continuous manufacture is possible, and, thereby, heat conductive molding which has high heat conductivity and light weight. The body 1E can be manufactured at a much lower cost. In addition, the cross-sectional shape of the extrusion molded body 6 (that is, the shape of the heat conductive molded body 1E) can be changed freely by changing the shape of the die 21d of the extrusion molding machine 21.

  Therefore, the method for producing a thermally conductive molded body according to the fourth embodiment shown in FIG. 8 is a method for producing a thermally conductive molded body comprising a thermally conductive fiber and an organic synthetic resin, and the thermal conductivity Introducing an organic synthetic resin into the extruder at the same time as or following the introduction step of bundling a large number of the active fibers into the extrusion molding machine while bundling the long fibers. A melting process for heating and melting, an extrusion process for extruding the heat conductive fiber in which a large number of the long fibers are bundled as a continuous block while impregnating the heat-melted organic synthetic resin, and a predetermined block. And a cutting step of cutting into lengths.

  Moreover, the heat conductive molded object 1E which concerns on this Embodiment 4 shown by FIG. 8 is a heat conductive molded object which consists of a heat conductive fiber and organic synthetic resin, Comprising: The said heat conductive fiber is a long fiber. As many bundles are bundled and introduced into an extrusion molding machine, an organic synthetic resin is put into the extrusion molding machine, heated and melted, and extruded as a continuous block while impregnating the thermally conductive fibers. Thereafter, the block is cut into a predetermined length.

  Next, the manufacturing method of the heat conductive molded object which concerns on the 1st modification of this Embodiment 4 is demonstrated with reference to FIG. In the first modification of the fourth embodiment, coal pitch-based carbon fiber 2Fa is used as the heat conductive fiber 2, and the hot melt nylon resin 3F, which is a thermoplastic resin, is used as the organic synthetic resin 3. ing.

  As shown in FIG. 9A, in the first modification of the fourth embodiment, the coal pitch-based carbon fiber 2Fa is drawn from the roving 14F and introduced into the mold 23 communicated with the extruder 22. At the same time, the nylon resin 3F for hot melt is charged into the extruder 22 and melted by heating to form a liquid, drawn out from the mold 23 while impregnating the carbon fiber 2Fa (impregnation step), and then cooled and solidified (solidification). Process).

  As shown in FIG. 9B, the resin-impregnated carbon fiber 2Fb is cut into a predetermined length by a cutting device (not shown) to form a resin-impregnated short fiber 2Fc (cutting step). Then, the resin-impregnated short fibers 2Fc are aligned and filled in the press mold 10 in the same direction by an unillustrated robot (alignment process).

  Then, as shown in FIG. 9C, the pressurizing mechanism 11 is operated to push the press die 12 into the press die 10, thereby the resin-impregnated short fibers 2Fc in which the hot melt nylon resin 3F is aligned. At the same time, the hot melt nylon resin 3F is squeezed out from a through-hole (not shown) while being heated and pressed in a direction perpendicular to the aligned direction (pressing step).

  Thereafter, the press mold 10 is cooled to completely cool and solidify the hot melt nylon resin 3F, and as shown in FIG. 9 (d), the carbon fibers 2F as the heat conductive fibers and the organic synthetic resin. The rectangular parallelepiped thermally conductive molded body 1F according to the first modification of the fourth embodiment, which is made of the nylon resin 3F, can be manufactured.

  Thus, in the manufacturing method of the heat conductive molded object which concerns on the 1st modification of this Embodiment 4 shown by FIG. 9, the extruder 22, the cutting device which is not shown, the robot which is not shown, and the pressurization mechanism 11 are provided. Since the provided press dies 10, 12 and the like are used, it can be easily automated, and a method for producing a thermally conductive molded body with higher mass productivity is obtained. Therefore, further cost reduction can be realized.

  That is, this method for producing a thermally conductive molded body is a method for producing a thermally conductive molded body composed of a thermally conductive fiber and a thermoplastic resin, and the thermoplastic resin is heated on the thermally conductive fiber. An impregnation step for impregnation in a fluidized state; a solidification step for cooling and solidifying the thermoplastic resin; and a cutting step for cutting the thermally conductive fibers impregnated with the solidified thermoplastic resin into solid short fibers of a predetermined length; An alignment process for aligning the solidified short fibers in a press mold, and a remelting / resoftening process for heating the press mold to remelt the thermoplastic resin into a molten state or resoften into a semi-fluid state. A pressing step of pressing the remelted or resoftened thermoplastic resin by the press mold together with the short fibers in a direction perpendicular to the aligned direction, and re-cooling and solidifying the thermoplastic resin again completely. A method for producing a thermally conductive molded article characterized by comprising a step.

  In this method for producing a thermally conductive molded body, the thermoplastic resin is cooled and solidified, then cut into solidified short fibers, and the solidified short fibers are aligned in a press mold. When the impregnated thermoplastic resin is solidified, it is stronger, easier to handle, and less likely to break, making it easier to automate each process with a cutting device and an alignment robot, and mass production with a low incidence of defective products The effect of becoming a method is obtained.

  Next, the manufacturing method of the heat conductive molded object which concerns on the 2nd modification of this Embodiment 4 is demonstrated with reference to FIG. In the second modification of the fourth embodiment, coal pitch-based carbon fibers 2Ga are used as the heat conductive fibers 2, and the organic synthetic resin 3 is a hot melt nylon resin 3G which is a thermoplastic resin. ing.

  As shown in FIG. 10A, in the second modification of the fourth embodiment, the coal pitch-based carbon fiber 2Ga is pulled out from the roving 14G and introduced into the mold 23 communicated with the extruder 22. At the same time, the hot melt nylon resin is charged into the extruder 22 and melted by heating to form a liquid, which is drawn out from the mold 23 while impregnating the carbon fiber 2Ga (impregnation step) and completely solidified (curing step).

  This cured carbon fiber 2Gb is cut into a predetermined length by a cutting device (not shown) to obtain a cured short fiber 2Gc (cutting step). On the other hand, the impregnation step, the curing step, and the cutting step are performed in the same manner using glass fiber (GF) to produce a cured short fiber 2Hc made of glass fiber. Then, as shown in FIG. 10B, the cured short fibers 2Gc and the cured short fibers 2Hc are mixed by a robot (not shown) at a ratio at which the desired thermal conductivity is obtained, and the inside of the press mold (not shown) Are aligned and filled in the same direction (alignment process).

  Then, as shown in FIG. 10 (c), by heating and compressing as shown by an arrow by a press mold (not shown), along with the cured short fibers 2Gc and 2Hc in which the cured hot melt nylon resin 3G is aligned, Excessive hot-melt nylon resin 3G is squeezed out from through holes (not shown) while being pressed in a direction perpendicular to the aligned direction (pressing step).

  Next, by cooling a press mold (not shown) to completely cool and solidify the hot melt nylon resin 3G, as shown in FIG. 10 (d), carbon fibers 2G as heat conductive fibers, fillers A heat conductive molded body 1Ga having a rectangular parallelepiped shape (thin plate shape having a rectangular surface) made of glass fiber 2H (reinforcing material) and nylon resin 3G as an organic synthetic resin is obtained.

  Subsequently, the surface and the back surface of the thermally conductive molded body 1Ga are subjected to surface polishing, thereby adjusting the plate thickness to the target thickness and improving the smoothness of the surface and the back surface, as shown in FIG. 10 (e). As shown in FIG. 10E, the thermally conductive sheet 8 is pasted on the front surface and the back surface of the polished thermally conductive molded body 1Gb to be polished with a thermally conductive adhesive. In this way, as shown in FIG. 10 (f), a rectangular parallelepiped thermally conductive molded body 1 </ b> G according to the second modification of the fourth embodiment can be manufactured.

  In the second modification of the fourth embodiment, a copper foil is used as the heat conductive sheet 8, and a silver paste is used as the heat conductive adhesive. The heat conductive sheet 8 is not limited to copper foil, and aluminum foil, stainless steel foil, or the like may be used. Various heat conductive adhesives other than silver paste are also used as the heat conductive adhesive. An agent can be used.

  Thus, in the manufacturing method of the heat conductive molded object which concerns on the 2nd modification of this Embodiment 4 shown by FIG. 10, the extruder 22, the cutting device which is not shown, the robot which is not shown, the pressurizing mechanism which is not shown Therefore, it is possible to easily automate the manufacturing method of the thermally conductive molded body with higher mass productivity. Therefore, further cost reduction can be realized.

  Moreover, in the heat conductive molded object 1G which concerns on the 2nd modification of this Embodiment 4, and its manufacturing method, not only the carbon fiber 2G as a heat conductive fiber but also the glass fiber 2H as a reinforcement is provided. Therefore, by adjusting the mixing ratio of the carbon fibers 2G and the glass fibers 2H, it is possible to easily manufacture the thermally conductive molded body 1G having the target thermal conductivity, and Since the amount used can be reduced, the thermally conductive molded body 1G can be manufactured at a lower cost.

  Furthermore, in the heat conductive molded object 1G which concerns on the 2nd modification of this Embodiment 4, and its manufacturing method, plate | board thickness is aimed at by carrying out surface grinding | polishing of the surface and back surface of the heat conductive molded object 1Ga. The thickness is adjusted and the smoothness of the front surface and the back surface is improved, and the heat conductive sheet 8 is attached to the front surface and the back surface, respectively, so that the heat conductivity of the heat conductive molded body 1G can be reduced without decreasing. The strength in the surface direction of the conductive molded body 1G can be improved, and the crack in the thickness direction of the thermally conductive molded body 1G can be prevented.

  Moreover, in the heat conductive molded object 1G which concerns on the 2nd modification of this Embodiment 4, and its manufacturing method, the heat conductive sheet 8 is thermally conductive on the surface and back surface of the ground heat conductive molded object 1Gb. Since it is pasted using a silver paste as an adhesive, there is no fear of reducing the thermal conductivity of the thermally conductive molded body 1G.

  As described above, in the thermally conductive molded body and the manufacturing method thereof according to the fourth embodiment, a material having a simple composition and high thermal conductivity can be manufactured, and high heat equivalent to or higher than that of metal. It is possible to obtain low-cost thermally conductive molded bodies 1E, 1F, and 1G that have a conductivity and are as light as an organic synthetic resin.

  In each of the above embodiments, only the case where coal pitch-based carbon fiber is used as the heat conductive fiber has been described. However, the heat conductive fiber is not limited to this, and other carbon fibers may be used. In addition, metal fibers (especially copper fibers are preferred), synthetic fibers coated with a highly thermally conductive material such as carbon or metal, and the like can be used.

  In each of the above embodiments, the case where an epoxy resin and a phenol resin, which are thermosetting resins, and a kind of hot melt nylon resin, which is a polyamide resin, is used as the organic synthetic resin has been described. As the organic synthetic resin, other thermosetting resins such as melamine resin, urea resin, unsaturated polyester resin, alkyd resin, polyurethane, thermosetting polyimide and the like can be used.

  Furthermore, as the organic synthetic resin, other thermoplastics such as polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, acrylic resin, polytetrafluoroethylene, polyamide resin, aramid resin, ABS resin, etc. It is also possible to use a resin.

  In practicing the present invention, the other steps of the method for producing a thermally conductive molded body, including the configuration, shape, quantity, material, size, connection relationship, production method, etc. of other parts of the thermally conductive molded body Is not limited to the above embodiments. Note that the numerical values given in the embodiments of the present invention are not all critical values, and certain numerical values indicate preferred values suitable for implementation, so even if the numerical values are slightly changed. The implementation is not denied.

1, 1A, 1B, 1C, 1D, 1E, 1F, 1G Thermally conductive molded body 2, 2A, 2B, 2C, 2D, 2E, 2F, 2G Thermally conductive fibers 2Bc, 2Cc, 2Dc, 2Fc Semi-cured short fibers 3, 3A, 3B, 3C, 3D, 3E, 3F, 3G Organic synthetic resin

Claims (13)

A thermally conductive molded body comprising a thermally conductive fiber and an organic synthetic resin,
The thermally conductive molded body, wherein the thermally conductive fibers are aligned in the same direction, and the gap is filled with the organic synthetic resin and compressed in a direction perpendicular to the same direction.   2. The thermally conductive molded article according to claim 1, wherein a volume content of the thermally conductive fiber is in a range of 64% to 90%.   3. The heat according to claim 1, wherein the thermally conductive fiber is a carbon fiber having a thermal conductivity in a range of 140 W / (m · K) to 900 W / (m · K). Conductive molded body.   Furthermore, the heat conductive molded object as described in any one of Claim 1 thru | or 3 containing the natural fiber, inorganic fiber, or organic fiber as a reinforcing material.   Furthermore, the heat conductive sheet | seat was affixed on the surface and back surface perpendicular | vertical with respect to the said same direction, The heat conductive molded object as described in any one of the Claims 1 thru | or 4 characterized by the above-mentioned. A method for producing a thermally conductive molded body comprising a thermally conductive fiber and an organic synthetic resin,
Cutting the thermally conductive fibers into short fibers of a predetermined length;
An alignment step of aligning the short fibers in a press mold;
An inflow step of allowing the organic synthetic resin to flow into the press mold in a fluid state;
A pressing step of pressing the organic synthetic resin together with the aligned short fibers in the direction perpendicular to the aligned direction by the pressing mold;
And a curing step of curing the organic synthetic resin. A method for producing a thermally conductive molded body comprising a thermally conductive fiber and an organic synthetic resin,
An impregnation step of impregnating the thermally conductive fiber with the organic synthetic resin in a fluid state;
A semi-curing step of semi-curing the organic synthetic resin into a semi-fluid state;
A cutting step of cutting the thermally conductive fibers impregnated with the semi-cured organic synthetic resin into semi-cured short fibers of a predetermined length;
An alignment step of aligning the semi-cured short fibers in a press mold;
A pressing step of pressing the semi-cured organic synthetic resin with the aligned semi-cured short fibers in a direction perpendicular to the aligned direction by the pressing mold;
And a curing step for curing the semi-cured organic synthetic resin. A method for producing a thermally conductive molded body comprising a thermally conductive fiber and a thermoplastic resin,
An impregnation step of heating the thermoplastic resin into the thermally conductive fiber and impregnating it in a fluid state;
A solidification step of cooling and temporarily solidifying the thermoplastic resin;
A cutting step of cutting the thermally conductive fibers impregnated with the solidified thermoplastic resin into solid short fibers of a predetermined length;
An alignment step of aligning the solidified short fibers in a press mold;
A remelting / resoftening step of heating the press mold to remelt the thermoplastic resin into a molten state or resoften into a semi-fluid state;
A pressing step of pressing the remelted or resoftened thermoplastic resin by the press die together with the short fibers in a direction perpendicular to the aligned direction;
And a re-solidification step of completely cooling and solidifying the thermoplastic resin again.   9. The press according to claim 6, wherein, in the pressing step, pressing and discharging an extra organic synthetic resin or an extra semi-cured organic synthetic resin from the press mold. 10. Manufacturing method of heat conductive molded object. A method for producing a thermally conductive molded body comprising a thermally conductive fiber and an organic synthetic resin,
An alignment step in which the thermally conductive fibers are aligned while being bundled and passed through a mold;
An extrusion molding step in which the organic synthetic resin is allowed to flow into the mold in a fluid state simultaneously with the alignment step and is extruded while impregnating the thermally conductive fibers;
A curing step of curing the organic synthetic resin;
The manufacturing method of the heat conductive molded object characterized by including the cutting process which cut | disconnects the said extrusion-molded molded object in the direction perpendicular | vertical to the said aligned direction.   The heat conductive fiber is a carbon fiber having a thermal conductivity in a range of 140 W / (m · K) to 900 W / (m · K), according to any one of claims 6 to 10. The manufacturing method of the heat conductive molded object as described in one.   The heat according to any one of claims 6 to 11, further comprising a natural fiber, an inorganic fiber, or an organic fiber as a reinforcing material in addition to the heat conductive fiber and the organic synthetic resin. A method for producing a conductive molded body.   After the curing step, further comprising a planar polishing step of planarly polishing the front surface and the back surface perpendicular to the aligned direction, and a pasting step of attaching a thermal conductive sheet to the surface and the back surface subjected to the planar polishing, respectively. The method for producing a thermally conductive molded body according to any one of claims 6 to 12, wherein:

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