JP4531354B2 - Heat conduction sheet - Google Patents
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- JP4531354B2 JP4531354B2 JP2003174592A JP2003174592A JP4531354B2 JP 4531354 B2 JP4531354 B2 JP 4531354B2 JP 2003174592 A JP2003174592 A JP 2003174592A JP 2003174592 A JP2003174592 A JP 2003174592A JP 4531354 B2 JP4531354 B2 JP 4531354B2
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Description
【０００１】
【発明の属する技術分野】
本発明は、プラズマディスプレイパネルや有機エレクトロルミネッセンスディスプレイと放熱板の間に介在され、これらの部材に発生した熱を放熱板へ伝導するための熱伝導シートに係り、特に、熱伝導シートの接着性やリペア性に優れた熱伝導シートに関する。尚、本発明において樹脂組成物の配合組成を示す「部」等の単位は、特に断らない限り質量基準で表す。
【０００２】
【従来の技術】
近年、大画面で、薄型かつ軽量の画像表示措置としてプラズマディスプレイや有機エレクトロルミネッセンスディスプレイ（以下、表示パネルという）が実用化されている。この表示パネルは、発光表示する際に内部放電によって発熱し、局部的に伸縮して破損や画質劣化が生じてしまう。このため、表示パネルの背面に熱伝導シートを介在させて放熱板を取り付け、発生した熱を放熱させる手段が提案されている。この際に介在させる熱伝導シートとしては、アクリル系モノマーに熱伝導フィラーおよび重合開始剤を分散させた組成物をナイフ塗工し、紫外線を塗工膜に照射し重合させたものが知られている（特許文献１参照。）。
【０００３】
【特許文献１】
特開平１１−２９２９９８号公報
【０００４】
【発明が解決しようとする課題】
ここで、上記表示パネル及び上記放熱板は、剛性のある板状体で曲折できないものである。このため、熱伝導シートを一方の部材に貼り付ける際には、熱伝導シート自体を曲折させて気泡を追い出しながら貼り付けることができるが、熱伝導シートの他方の面に他方の部材を貼り付ける際には、すでに貼り付けた部材が曲折できないため、貼り付け面が全面同時に接触してしまう。このため、両者の界面に気泡が巻き込まれて実質的な接着面積が大幅に減少すると共に、巻き込まれた気泡が断熱材となって熱伝導率が大幅に低減してしまうという問題があった。
【０００５】
さらに、前記のように表示パネル、熱伝導シート及び放熱板を貼り合せた後に、貼り損ないや、表示パネル又は放熱板に不具合が生じた場合、これらを貼替える必要が有り、その際の離脱が容易であること（以下「リペア性」と記す。）が要求されるが、該表示パネル及び該放熱板が平滑面であり、曲折できないために剥がしにくいという問題があった。
【０００６】
本発明は、前記のように表示パネルの背面に熱伝導シートを介して放熱板を固定する際に、これらの界面に巻き込まれた気泡を逃がすことで実質的な接着面積を維持して熱伝導率を向上させると共に、貼替えの際のリペア性にも優れる熱伝導シートを提供することを課題とする。
【０００７】
【課題を解決するための手段】
本発明者等は、前記課題を達成するために鋭意検討した結果、本発明に至った。即ち、本発明は、アクリル系樹脂に熱伝導フィラーを配合した熱伝導性組成物をシート状に成形して得られた熱伝導基材と、該熱伝導基材の一面又は両面へ熱可塑性樹脂エマルジョンとしてアクリル系樹脂エマルジョン又はアクリル系樹脂とウレタン系樹脂の混合エマルジョンをシート状に成形して得られた接着性表層を積層して得られる熱伝導シートにおいて、粘度１０００〜１５０００ｃｐｓの熱可塑性樹脂エマルジョンを機械発泡機で熱可塑性樹脂エマルジョンと空気の混合割合を容積比で２：１〜１：５で混合し、気泡を分散させた発泡エマルジョンを熱伝導基材に塗工した、接着性表層が空孔を有する平滑な表面を形成し、該表面の空孔は内部の空孔へと細径管にて連続した構造を有し、空孔の平均径が１０〜３０μｍであり、接着性表層の空隙率が５〜７０％であり、接着性表層の厚さが１０〜３００μｍであることを特徴とする熱伝導シート及びその製造方法である。接着性表層は、熱可塑性樹脂エマルジョンの樹脂成分１００部と、熱伝導フィラー５〜２００部を含むことが好ましい。
一方で本発明は、該熱伝導シートを表示パネル又は放熱板から離脱する際に、該熱伝導シートの空孔を有する接着性表層に、界面活性剤を含む水溶液又は溶剤等を含浸させて接着力を低下させることを特徴とする、積層表示パネルからの熱伝導シートの離脱方法も含んでいる。
【０００８】
【発明の実施の形態】
本発明の熱伝導シートは、熱伝導基材と、熱伝導基材の一面又は両面に積層された接着性表層を有するものであり、該接着性表層の表面及び内部に配置された空孔から、表示パネルの背面に放熱板を固定する際に巻き込まれた気泡を逃がすことで接着面積を維持し、熱伝導率を向上させたことを特徴とするものである。
【０００９】
本発明の熱伝導基材は、有機結合剤に熱伝導フィラーを配合した熱伝導性組成物をシート状に成形することにより得られる。この有機結合剤は、一般的に熱伝導シートの素材として用いられているものであれば特に限定されるものではなく、具体的には、クロロプレンゴム、ブチルゴム、ウレタンゴム、ニトリル−ブタジエン系ゴム、スチレン−ブタジエン系ゴム、ポリエステル系樹脂、ポリエチレン系樹脂、ポリ塩化ビニル系樹脂、ポリウレタン樹脂、セルロール系樹脂、ＡＢＳ樹脂、シリコーン樹脂、フェノール樹脂、アクリル系樹脂、アミド系樹脂、イミド系樹脂、或いはそれらの共重合体などを適宜用いることが出来るが、モノマーの状態で後述するフィラー等との混合が容易にできることや、その分子構成の調整が容易であるといったような点で、アクリル系樹脂が好ましい。
【００１０】
本発明でいうアクリル系樹脂とは、アクリル酸、メタクリル酸、及びそれらの誘導体の２種以上からなる共重合体であり、一般的なものを適宜選択して採用できる。具体的には、メチル基、エチル基、プロピル基、ブチル基、イソオクチル基、イソノニル基、イソデシル基、ドデシル基、ラウリル基、トリデシル基、ペンタデシル基、ヘキサデシル基、ヘプタデシル基、オクタデシル基、ノナデシル基、及びエイコキシル基などの、炭素数が２０以下のアルキル基を有する（メタ）アクリル酸エステルの１種以上からなる重合体もしくは共重合体が挙げられる。
【００１１】
又、一部の共重合成分として、アクリル酸ヒドロキエチル、メタクリル酸ヒドロキシエチル、アクリル酸ヒドリキシプロピル、メタクリル酸ヒドロキシプロピル、Ｎ―メチロールアクリルアミド、アクリロニトリル、メタクリロニトリル、アクリル酸グリシジル、酢酸ビニル、スチレン、イソプレン、ブタジエン、イソブチレン、及びビニルエーテル等の１種以上を含有したものであっても良い。
【００１２】
また、熱伝導基材に配合する熱伝導フィラーとしては、十分な熱伝導性を与える事のできるものであれば、一般的な無機フィラーを用いる事ができ、特に限定されるものではなくいが、具体例としては、アルミナ、水酸化アルミニウム、ボロンナイトライド、酸化珪素及び窒化アルミニウム等が挙げられる。中でも水酸化アルミニウムは難燃性が得られる点で特に好ましい。
【００１３】
該熱伝導基材は、例えば、アクリル系樹脂の場合は、そのモノマー中に熱伝導フィラーを所定量配合して塗料化し、これを合成樹脂フィルム、紙又は金属等の支持体上にドクターブレード等により所定の厚さに塗工し、乾燥することにより得ることができる。本発明の熱伝導基材シートの成形方法は、前記方法に限定されるものではなく、他の例としては、熱伝導フィラーを配合した樹脂組成物を押出成形する方法などが挙げられる。
【００１４】
熱伝導基材の厚さは特に限定されるものではなく、この熱伝導シートを用いて積層表示パネルを形成するのに用いる表示パネルや放熱板の大きさによって適宜設定すれば良い。また、この熱伝導基材は、単層のものであっても複数の層から構成されるものであっても良い。
【００１５】
本発明の接着性表層は、熱可塑性樹脂エマルジョンをシート状に成形することにより得られる。熱可塑性樹脂エマルジョンとしては、一般的に樹脂コート用いられるものから適宜選択して採用でき、具体例としては、ウレタン系樹脂、アクリル系樹脂、フェノール系樹脂、ポリエステル系樹脂、ポリオレフィン系樹脂、フッ素系樹脂、ポリアセタール樹脂、エポキシ系樹脂、アルキツド樹脂、ブタジエン系合成ゴム等の１種又は２種以上混合した樹脂をエマルジョンとしたものを用いることが出来る。前記の熱伝導性基材としてアクリル系樹脂を用いたものを用いる場合は、基材層との密着性等の点で、この接着性表層としてもアクリル系樹脂のエマルジョンを用いることが好ましい。更に、接着性表層の空孔を形成が容易である点で、アクリル系樹脂とウレタン系樹脂の混合エマルジョンを用いることがより好ましい。
【００１６】
本発明の接着性表層は、熱可塑性樹脂エマルジョンの樹脂成分１００部に対して熱伝導フィラーを５〜２００部配合させることが、接着性表層の熱伝導度を増加させ、熱伝導シート全体の熱伝導効率を向上させる点で好ましい。
【００１７】
接着性表層に配合する熱伝導フィラーは、前記の熱伝導基材と同様に、アルミナ、ボロンナイトライド、酸化珪素、水酸化アルミニウム又は水酸化マグネシウム等の一般的な熱伝導フィラーから適宜選択して用いることができる。
【００１８】
これらの熱伝導フィラーが５部未満では熱伝導率を向上させるという効果が不十分となる場合が有り、２００部を超えると接着性表層の剛性が上がりすぎて表示パネルや放熱板への密着性が損なわれる恐れが有る。
【００１９】
本発明の接着性表層は、空孔を有する平滑な表面を形成し、該表面の空孔は内部の空孔へと細径管にて連続した構造を有している。このことにより、この熱伝導シートを表示パネルや放熱板に貼付する際に、シートとこれらの板状物の間の空気を、熱伝導シートの側面に逃がすことができ、実質的な接着面積を飛躍的に増加させることが可能となる。
【００２０】
この接着性表層の空孔の平均径は１０〜２００μｍであることが好ましい。又、この空孔の平均径が１０μｍ未満では、巻き込まれた気泡を逃がす効果が小さく接着面積が小さくなり、その結果として十分な熱伝導度が得られない恐れが有る。又、界面活性剤を含む水溶液や溶剤等が含浸し難くなって、リペア性も低下する場合がある。一方で空孔の平均径が２００μｍを超えると、リペア性はむしろ向上するが、表示パネルや放熱板に物理的に密着する面積が不足し、結果として十分な熱伝導度が得られない場合がある。
【００２１】
また、接着性表層における空隙率は、５〜７０％が好ましく、さらに好ましくは１０〜５０％である。空隙率が５％未満では巻き込まれた気泡を逃がす効果が不十分となり、接着面積が減少し、熱伝導度が低下してしまう場合がある。又、界面活性剤を含む水溶液や溶剤等が含浸し難くなるためリペア性も低下することがある。一方で空隙率が７０％を超えると、リペア性はむしろ向上するが、表示パネルや放熱板に密着する面積が不足して、これらを安定的に固定できなくなる場合がある。
【００２２】
本発明において、前記の空孔の平均径及び空隙率とは、一般的に知られている顕微鏡法（角田光雄著、「機能性エマルジョンの技術・評価とその応用」、シーエムシー出版、２００２年４月、p113）に準じて平均径及び空隙率を測定した値である。
【００２３】
接着性表層の製造方法は、前記の細径管で連続した構造の空孔や空隙率を有するシートが得られる方法であれば特に限定されるものではなく、熱可塑性樹脂エマルジョンからシートもしくはフィルムを成形する一般的に知られている方法から適宜選択して用いることが出来る。
【００２４】
例えば、熱可塑性樹脂エマルジョンの粘度や熱可塑性樹脂エマルジョンに含まれる空気の量、オークスミキサーの混合時間などを調整することで、前記の空孔の平均径や空隙率を適宜設計することができる。これを合成樹脂フィルム、紙、金属等の支持体上にドクターブレード等により所定の厚さに塗工し、乾燥等の各工程の条件を選定することにより本発明の接着性表層を得ることができる。
【００２５】
前記の空孔や空隙率を調整する方法の、より好ましい例としては以下のような方法があげられる。熱可塑性樹脂エマルジョンとしてウレタン樹脂とアクリル樹脂エマルジョンを所定量混合した混合エマルジョンを、オークスミキサー等の機械発泡機にて空気と混合して、気泡を分散させた発泡エマルジョンを調整する。その際に、熱可塑性樹脂エマルジョンの粘度は、適切な気泡の径や状態を得る上で１０００〜１５０００ｃｐｓが好ましい。また、熱可塑性樹脂エマルジョンと空気との混合割合は、容積比で２：１〜１：５、ミキサーの混合時間は、３０分〜１２０分が好ましい。次にこれをＰＥＴ等のセパレータフィルム上にナイフコーターにより所定の厚さになるように塗工し、乾燥機にて乾燥することにより、目的の空孔の平均径及び空隙率を有する接着性表層を得ることができる。また、この方法においては、熱可塑性樹脂エマルジョンと空気の混合割合及びミキサーの混合時間を変化させることで、空孔の平均径及び空隙率を調整することが可能である。
【００２６】
この接着性表層の厚さは、１０〜３００μｍの範囲が好ましい。厚さが１０μｍ未満では巻き込まれた気泡を逃がす効果が不十分となり、接着面積が減少してしまうことがあり、又界面活性剤を含む水溶液や溶剤等が含浸し難くなりリペア性も低下する場合がある。厚さが３００μｍを超えると接着性表層自体が断熱層となって熱伝導率が低下する恐れがある。
【００２７】
本発明の熱伝導シートを構成する熱伝導基材及び接着性表層には、前記の発明の目的に反しない範囲で、改質剤、老化防止剤、熱安定剤、粘度調節剤、架橋剤、着色剤、難燃剤等を添加しても良い。また、必要なら接着性表層に起泡剤、整泡剤等を添加しても良い。
【００２８】
本発明の熱伝導シートは、前記の熱伝導基材の一面又は両面に、前記の空孔及び空隙率を有する接着性表層を、一般的な方法で積層することによって得られる。
【００２９】
本発明の熱伝導シートは、表示パネルと放熱板の間に配置して積層し用いられる。熱伝導基材の一面のみに接着性表層を有する熱伝導シートを用いる場合は、表示パネル又は放熱板の、初めに貼り付ける部材に、熱伝導シートのタック力を利用して接着性表層を有さない面を、貼り付けることが望ましい。即ち、初めに貼り付ける際は、前記のように柔軟性のある熱伝導シートを曲折させて気泡を追い出しながら貼り付けることにより、気泡を追い出しながら均一に接着することができ、熱伝導シートと放熱板等との界面での十分な熱伝導が実現できる。そのようにして得られた、表示パネル又は放熱板と熱伝導シートを積層したものを、他の部材（表示パネル又は放熱板）の表面に、接着性表層の側を、表示パネルに問題を生じない程度の適切な圧力で圧着することにより、前記のような実質的接着面積が大きく、良好な熱伝導性を有する積層表示パネルが得られる。
【００３０】
熱伝導基材の両面に該表層を有する熱伝導性シートの場合には、表示パネル、熱伝導シート及び放熱板を順次重ねておいて、適切な圧力で加圧し接着することで、実質的な接着面積が大きく、良好な熱伝導性を有する積層表示パネルが得られる。
【００３１】
一方で、前記のように表示パネル、熱伝導シート及び放熱板を貼り合せた後に、貼り損ないや、表示パネル又は放熱板に不具合が生じた場合、これらを貼替える必要が有る。本発明の熱伝導シートにおいては、その接着性表層の表面及び内部に配置された空孔に、カルボン酸塩やスルホン酸塩、硫酸エステル塩等の界面活性剤を含む水溶液又はイソプロピルアルコールやエタノール等の溶剤を含浸させることにより表示パネル及び放熱板への接着力を低下させて、リペアを容易に行うことができる。また、界面活性剤の水溶液濃度は、５〜３０％とすることが好ましい。５未満では、接着力低下の効果が十分得られない場合があり、３０を超えると空孔への含浸が困難となる恐れが有る。
【００３２】
【実施例】
本発明を実施例により、更に具体的に説明する。
（実施例１）
アクリル系共重合体を水に分散させたエマルジョン（高圧ガス工業株式会社製ぺガール８５１；樹脂成分５５％）の樹脂成分１００部に対して、水酸化アルミニウム（昭和電工株式会社製 Ｈ−３２）を１３５部配合した熱伝導性組成物を、ドクターブレードによりＰＥＴセパレータ上に塗工し乾燥させて厚さ９５０μｍのシート状の熱伝導基材を得た。一方で、アクリル系共重合体を水に分散させたエマルジョン（一方社油脂工業株式会社製 ＡＥ−１５０；樹脂成分５０％）の粘度を水を加えて１２００ｃｐｓに調整し、空気との混合割合を１対１の容積比として、オークスミキサーにて１時間混合した。この混合物をドクターブレードによりＰＥＴセパレータ上に塗工し、乾燥させて厚さ５０μｍの接着性表層を得た。この接着性表層は、平均径３０μｍ、空隙率１０％の連続した空孔を有していた。次いで前記の熱伝導基材の片面にこの接着性表層をラミネータロールを通して積層し熱伝導シートを作製した。
【００３３】
（実施例２）
熱伝導基材の厚さを９００μｍとし、接着性表層を熱伝導基材の両面に積層した以外は、実施例１と同様にして熱伝導シートを作成した。
（実施例３）
接着性表層として、アクリル系共重合体のエマルジョンに、熱伝導フィラーとして水酸化アルミニウム（昭和電工株式会社製 Ｈ−３２）をエマルジョンの樹脂成分１００部に対して１０部添加した混合物を用いた以外は、実施例１と同様にして熱伝導シートを作製した。
【００３４】
（比較例１）
熱伝導基材の厚さを１０００μｍとし、接着性表層を積層しなかった以外は、実施例１と同様にして熱伝導シートを得た。
（比較例２）
アクリル系共重合体のエマルジョンに、空気を混合しないで接着性表層を成形した以外は、実施例１と同様にして熱伝導シートを作成した。得られた熱伝導シートの接着性表層は、前記のような空孔のないものであった。
（比較例３）
アクリル系共重合体のエマルジョンに、化学発泡剤としての重曹を樹脂成分１００部に対して３部添加して、空気を混合しないで接着性表層を成形した以外は、実施例１と同様にして熱伝導シートを作製した。
【００３５】
（評価方法）
本発明の各実施例及び比較例の熱伝導シートの特性評価を、以下の評価法で行い、評価結果を表１に纏めて示した。尚、これらの評価法は、本発明の効果を示す為の方法の一例を示すものである。
１．接着割合の評価
接着割合は、熱伝導シートを表示パネルや放熱板へ貼り付けた際の気泡の巻き込み度合いを表すものである。試験サンプルは、アルミニウム板に各実施例及び比較例の熱伝導シートの接着性表層が積層されていない面（実施例２のみ接着性表層の片面）を空気が入らないように曲折しながら貼り付け、２kgのローラで１往復させ圧着させた後、熱伝導シートの接着性表層上に縦２１０ｍｍ、横３００ｍｍ、厚さ５ｍｍのガラス板を静かに載置し、２３℃で７２時間養生させて作製した。この試験サンプルのガラス面の上部分から、貼り付け面のデジタル写真を撮影し、画像処理して得られた画像ドット数から接着割合を算出した。
【００３６】
２．熱伝導度
熱伝導度は、熱伝導シート全体の熱伝導度を表すものである。熱伝導度試験の試験サンプルは、２ｃｍ×３ｃｍの長方形に調整した熱伝導シートを、ヒーターブロックと放熱ブロックの間に介在させ、２０ｇ／ｃｍ２の圧力で３０分間加圧した後に圧力を開放した。続いてヒーターブロックに伝熱量５Ｗで４分間印加した後に、ヒーターブロックと放熱ブロックとの温度差を測定し、伝熱量とサンプルの厚さの積の値を、伝熱面積と温度差の積の値で除算して算出した。
【００３７】
３．接着保持力
接着保持力は、熱伝導シートを表示パネルや放熱板へ貼り付ける際の固定安定度合いを表すものである。接着保持力の試験サンプルは、接着割合の試験サンプルと同様にして得られたものである。測定方法は、作製したサンプルのアルミニウム板とガラス板が、面方向へ、２００ｇｆの力でせん断される用に治具に取り付けて１２０℃のギヤオーブンに吊り下げ、両者が剥離して落下するまでの時間を測定したものである。この接着保持力の試験にあっては、５００時間でを越えて落下しない試料については、５００時間で測定を打ち切った。
【００３８】
４．リペア性
リペア性は、熱伝導シートを表示パネルや放熱板へ貼り付けた後、それぞれを取り外す際の容易さを表すものである。リペア性の試験サンプルは、接着割合の試験サンプルと同様にして得られたものである。測定方法は、作製したサンプルを界面活性剤としての直鎖アルキルベンゼンスルホン酸塩を含む１０％水溶液中へ全体が浸るように設置し、２４時間放置後に取り出し、ドライバーのように先端が平板状に尖っている治具を用いて表示パネルと放熱板を取り外そうとした際の容易さを測定したものである。このリペア性の試験においては、表示パネルおよび放熱板を変形又は破壊することなく容易に取り外しができるものを○、容易に取り外しができずに表示パネルおよび放熱板を変形又は破壊してしまうものを×とした。
【００３９】
【表１】
本発明の実施例の熱伝導シートは、いずれもアルミニウム板との接着割合が良好であり、熱伝導度、接着保持力及びリペア性のいずれも良好であった。それに対して、接着性表層のない比較例１の熱伝導シートでは、接着割合、リペア性が不十分であり、接着性表層が空孔を有しない比較例２や空孔が独立気泡である比較例３の熱伝導シートでは、接着割合、熱伝導度及びリペア性のいずれも不十分なものであり、比較例３は、接着保持力も劣るものであった。
【００４１】
【発明の効果】
本発明の熱伝導シートは、細径管にて連続した構造を有する空孔を有する接着性表層を設けたことにより、表示パネルの背面に放熱板を固定する際に、これらの界面に巻き込まれた気泡を効果的に逃がすことで接着面積を拡大することができ、その結果として熱伝導率や接着保持力を向上させることができる。また、上記接着性表層の表面及び内部に配置された空孔に、カルボン酸塩やスルホン酸塩、硫酸エステル塩等の界面活性剤を含む水溶液又はイソプロピルアルコールやエタノール等の溶剤を含浸させることにより、表示パネル及び放熱板への接着力を低下させてリペア性を向上させることができる。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a heat conductive sheet that is interposed between a plasma display panel or an organic electroluminescence display and a heat radiating plate and conducts heat generated in these members to the heat radiating plate. It is related with the heat conductive sheet excellent in property. In the present invention, units such as “parts” indicating the composition of the resin composition are expressed on a mass basis unless otherwise specified.
[0002]
[Prior art]
In recent years, a plasma display and an organic electroluminescence display (hereinafter referred to as a display panel) have been put into practical use as a large-screen, thin and lightweight image display measure. The display panel generates heat due to internal discharge when performing light emission display, and locally expands and contracts to cause breakage and image quality deterioration. For this reason, means has been proposed for dissipating the generated heat by attaching a heat dissipation plate with a heat conductive sheet interposed on the back surface of the display panel. As a heat conductive sheet to be interposed at this time, a composition in which a composition in which a heat conductive filler and a polymerization initiator are dispersed in an acrylic monomer is applied with a knife, and ultraviolet rays are irradiated onto the coating film to be polymerized is known. (See Patent Document 1).
[0003]
[Patent Document 1]
Japanese Patent Laid-Open No. 11-292998
[Problems to be solved by the invention]
Here, the display panel and the heat dissipation plate cannot be bent with a rigid plate-like body. For this reason, when the heat conductive sheet is attached to one member, it can be attached while bending the heat conductive sheet itself to expel bubbles, but the other member is attached to the other surface of the heat conductive sheet. At this time, since the already pasted member cannot be bent, the pasted surface comes into contact with the entire surface at the same time. For this reason, there is a problem that bubbles are involved in the interface between the two and the substantial adhesion area is greatly reduced, and the incorporated bubbles become a heat insulating material and the thermal conductivity is greatly reduced.
[0005]
Furthermore, after bonding the display panel, the heat conductive sheet and the heat sink as described above, if there is a failure in bonding or if there is a problem with the display panel or the heat sink, it is necessary to replace them. Although it is required to be easy (hereinafter referred to as “repair property”), there is a problem that the display panel and the heat dissipation plate are smooth surfaces and cannot be bent and thus are difficult to peel off.
[0006]
In the present invention, when the heat sink is fixed to the back surface of the display panel via the heat conductive sheet as described above, the heat conduction can be achieved by maintaining the substantial bonding area by releasing the bubbles entrained in these interfaces. It is an object of the present invention to provide a heat conductive sheet that improves the rate and is excellent in the repairability at the time of replacement.
[0007]
[Means for Solving the Problems]
As a result of intensive studies to achieve the above-mentioned problems, the present inventors have arrived at the present invention. That is, the present invention relates to a heat conductive substrate obtained by molding a heat conductive composition in which a heat conductive filler is blended with an acrylic resin into a sheet shape, and a thermoplastic resin on one or both surfaces of the heat conductive substrate. A thermoplastic resin emulsion having a viscosity of 1000 to 15000 cps in a heat conductive sheet obtained by laminating an adhesive surface layer obtained by forming an acrylic resin emulsion or a mixed emulsion of an acrylic resin and a urethane resin into a sheet as an emulsion. The adhesive surface layer was obtained by mixing the foamed emulsion in which the mixing ratio of the thermoplastic resin emulsion and air in a volume ratio of 2: 1 to 1: 5 with a mechanical foaming machine was dispersed on the heat conductive substrate. A smooth surface having pores is formed, and the pores on the surface have a structure continuous to the internal pores by a small diameter tube, the average diameter of the pores is 10 to 30 μm, Sexual surface a porosity of 5 to 70%, and the thermal conductive sheet and a manufacturing method thereof, wherein the thickness of the adhesive surface is 10 to 300 [mu] m. The adhesive surface layer preferably contains 100 parts of a resin component of a thermoplastic resin emulsion and 5 to 200 parts of a heat conductive filler.
On the other hand, in the present invention, when the thermal conductive sheet is detached from the display panel or the heat sink, the adhesive surface layer having pores of the thermal conductive sheet is impregnated with an aqueous solution or a solvent containing a surfactant. The method also includes a method of detaching the heat conductive sheet from the multilayer display panel, which is characterized by reducing the force.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
The heat conductive sheet of the present invention has a heat conductive base material and an adhesive surface layer laminated on one or both surfaces of the heat conductive base material. The adhesive area is maintained by releasing air bubbles that are involved when fixing the heat radiating plate to the back surface of the display panel, and the thermal conductivity is improved.
[0009]
The heat conductive substrate of the present invention is obtained by molding a heat conductive composition in which a heat conductive filler is blended into an organic binder into a sheet shape. This organic binder is not particularly limited as long as it is generally used as a material for a heat conductive sheet. Specifically, chloroprene rubber, butyl rubber, urethane rubber, nitrile-butadiene rubber, Styrene-butadiene rubber, polyester resin, polyethylene resin, polyvinyl chloride resin, polyurethane resin, cellulose resin, ABS resin, silicone resin, phenol resin, acrylic resin, amide resin, imide resin, or those However, an acrylic resin is preferable in that it can be easily mixed with a filler, which will be described later, in the monomer state, and the molecular structure can be easily adjusted. .
[0010]
The acrylic resin referred to in the present invention is a copolymer composed of two or more of acrylic acid, methacrylic acid, and derivatives thereof, and general ones can be appropriately selected and employed. Specifically, methyl group, ethyl group, propyl group, butyl group, isooctyl group, isononyl group, isodecyl group, dodecyl group, lauryl group, tridecyl group, pentadecyl group, hexadecyl group, heptadecyl group, octadecyl group, nonadecyl group, And a polymer or copolymer comprising at least one (meth) acrylic acid ester having an alkyl group having 20 or less carbon atoms, such as an ecoxyl group.
[0011]
Some copolymer components include hydroxyethyl acrylate, hydroxyethyl methacrylate, hydroxypropyl acrylate, hydroxypropyl methacrylate, N-methylolacrylamide, acrylonitrile, methacrylonitrile, glycidyl acrylate, vinyl acetate, styrene. , One or more of isoprene, butadiene, isobutylene, vinyl ether and the like may be used.
[0012]
Moreover, as a heat conductive filler mix | blended with a heat conductive base material, if it can give sufficient heat conductivity, a general inorganic filler can be used, It is not specifically limited. Specific examples include alumina, aluminum hydroxide, boron nitride, silicon oxide, and aluminum nitride. Among these, aluminum hydroxide is particularly preferable in terms of obtaining flame retardancy.
[0013]
For example, in the case of an acrylic resin, the heat conductive base material is blended with a predetermined amount of a heat conductive filler in the monomer to form a paint, and this is a doctor blade or the like on a support such as a synthetic resin film, paper, or metal. Can be obtained by coating to a predetermined thickness and drying. The molding method of the heat conductive substrate sheet of the present invention is not limited to the above method, and other examples include a method of extruding a resin composition containing a heat conductive filler.
[0014]
The thickness of the heat conductive substrate is not particularly limited, and may be set as appropriate depending on the size of the display panel and the heat radiating plate used to form the laminated display panel using this heat conductive sheet. In addition, the heat conductive substrate may be a single layer or a plurality of layers.
[0015]
The adhesive surface layer of the present invention can be obtained by molding a thermoplastic resin emulsion into a sheet shape. As the thermoplastic resin emulsion, it can be appropriately selected from those generally used for resin coating. Specific examples include urethane resins, acrylic resins, phenol resins, polyester resins, polyolefin resins, fluorine resins. Resins, polyacetal resins, epoxy resins, alkyd resins, butadiene synthetic rubbers, and the like can be used as emulsions. In the case of using an acrylic resin as the heat conductive substrate, it is preferable to use an acrylic resin emulsion as the adhesive surface layer in terms of adhesion to the substrate layer. Furthermore, it is more preferable to use a mixed emulsion of an acrylic resin and a urethane resin in that it is easy to form pores in the adhesive surface layer.
[0016]
In the adhesive surface layer of the present invention, adding 5 to 200 parts of the heat conductive filler to 100 parts of the resin component of the thermoplastic resin emulsion increases the heat conductivity of the adhesive surface layer, and the heat of the entire heat conductive sheet. This is preferable in terms of improving the conduction efficiency.
[0017]
The heat conductive filler to be blended in the adhesive surface layer is appropriately selected from general heat conductive fillers such as alumina, boron nitride, silicon oxide, aluminum hydroxide or magnesium hydroxide as in the case of the heat conductive substrate. Can be used.
[0018]
If these thermal conductive fillers are less than 5 parts, the effect of improving the thermal conductivity may be insufficient, and if they exceed 200 parts, the adhesive surface layer will be too rigid and adhere to display panels and heat sinks. May be damaged.
[0019]
The adhesive surface layer of the present invention forms a smooth surface having pores, and the pores on the surface have a structure that is continuous to the internal pores by a small diameter tube. As a result, when the heat conductive sheet is attached to a display panel or a heat sink, air between the sheet and these plate-like objects can escape to the side surface of the heat conductive sheet, and a substantial bonding area can be obtained. It becomes possible to increase dramatically.
[0020]
The average diameter of the pores in the adhesive surface layer is preferably 10 to 200 μm. Further, if the average diameter of the pores is less than 10 μm, the effect of escaping the entrained bubbles is small and the bonding area is small, and as a result, there is a possibility that sufficient thermal conductivity cannot be obtained. Moreover, it becomes difficult to be impregnated with an aqueous solution or a solvent containing a surfactant, and the repairability may be lowered. On the other hand, when the average diameter of the pores exceeds 200 μm, the repair property is rather improved, but there is a case where the area that physically adheres to the display panel or the heat sink is insufficient, and as a result, sufficient thermal conductivity cannot be obtained. is there.
[0021]
Further, the porosity in the adhesive surface layer is preferably 5 to 70%, more preferably 10 to 50%. If the porosity is less than 5%, the effect of escaping entrained bubbles becomes insufficient, the adhesion area is reduced, and the thermal conductivity may be lowered. Moreover, since it becomes difficult to be impregnated with an aqueous solution or a solvent containing a surfactant, the repair property may be lowered. On the other hand, if the porosity exceeds 70%, the repair property is rather improved, but the area that is in close contact with the display panel or the heat sink is insufficient, and these may not be stably fixed.
[0022]
In the present invention, the average diameter and porosity of the above-mentioned pores are generally known microscopic methods (Mitsuo Kakuda, “Technology / Evaluation of Functional Emulsions and Applications”, CMC Publishing, 2002). In April, the average diameter and porosity were measured according to p113).
[0023]
The method for producing the adhesive surface layer is not particularly limited as long as it is a method capable of obtaining a sheet having pores and porosity having a continuous structure with the above-mentioned small-diameter tube, and a sheet or film is formed from a thermoplastic resin emulsion. The method can be appropriately selected from generally known methods for molding.
[0024]
For example, by adjusting the viscosity of the thermoplastic resin emulsion, the amount of air contained in the thermoplastic resin emulsion, the mixing time of the Oaks mixer, and the like, the average diameter and porosity of the pores can be appropriately designed. The adhesive surface layer of the present invention can be obtained by applying this to a predetermined thickness with a doctor blade or the like on a support such as a synthetic resin film, paper, or metal, and selecting conditions for each step such as drying. it can.
[0025]
The following method is mentioned as a more preferable example of the method of adjusting the said void | hole and the porosity. A mixed emulsion obtained by mixing a predetermined amount of a urethane resin and an acrylic resin emulsion as a thermoplastic resin emulsion is mixed with air in a mechanical foaming machine such as an Oaks mixer to prepare a foamed emulsion in which bubbles are dispersed. At that time, the viscosity of the thermoplastic resin emulsion is preferably 1000 to 15000 cps for obtaining an appropriate bubble diameter and state. Further, the mixing ratio of the thermoplastic resin emulsion and air is preferably 2: 1 to 1: 5 by volume ratio, and the mixing time of the mixer is preferably 30 minutes to 120 minutes. Next, this is coated on a separator film such as PET with a knife coater so as to have a predetermined thickness, and dried with a drier, whereby an adhesive surface layer having an average diameter and porosity of the target pores. Can be obtained. Moreover, in this method, it is possible to adjust the average diameter and porosity of the pores by changing the mixing ratio of the thermoplastic resin emulsion and air and the mixing time of the mixer.
[0026]
The thickness of the adhesive surface layer is preferably in the range of 10 to 300 μm. When the thickness is less than 10 μm, the effect of escaping entrained bubbles becomes insufficient, the adhesion area may decrease, and the aqueous solution or solvent containing a surfactant is difficult to be impregnated and the repair property is also reduced. There is. If the thickness exceeds 300 μm, the adhesive surface layer itself becomes a heat insulating layer, which may reduce the thermal conductivity.
[0027]
In the heat conductive substrate and the adhesive surface layer constituting the heat conductive sheet of the present invention, a modifier, an anti-aging agent, a heat stabilizer, a viscosity modifier, a crosslinking agent, as long as the object of the invention is not violated. Coloring agents, flame retardants and the like may be added. Further, if necessary, a foaming agent, a foam stabilizer or the like may be added to the adhesive surface layer.
[0028]
The heat conductive sheet of this invention is obtained by laminating | stacking the adhesive surface layer which has the said void | hole and the porosity on the one surface or both surfaces of the said heat conductive base material by a general method.
[0029]
The heat conductive sheet of this invention is arrange | positioned and used between a display panel and a heat sink. When a heat conductive sheet having an adhesive surface layer is used only on one surface of the heat conductive substrate, the adhesive member is attached to the first member of the display panel or heat sink using the tack force of the heat conductive sheet. It is desirable to affix the surface that does not. That is, at the time of pasting, the flexible heat conductive sheet is bent as described above and adhered while expelling the bubbles, so that the bubbles can be uniformly adhered while expelling the bubbles. Sufficient heat conduction at the interface with a plate or the like can be realized. The display panel or the heat sink and the heat conductive sheet obtained as described above are laminated on the surface of another member (display panel or heat sink), the adhesive surface layer side, and the display panel has a problem. By press-bonding with an appropriate pressure that is not present, a multilayer display panel having a large substantial adhesion area as described above and having good thermal conductivity can be obtained.
[0030]
In the case of the heat conductive sheet having the surface layer on both surfaces of the heat conductive substrate, the display panel, the heat conductive sheet, and the heat radiating plate are sequentially stacked, and then pressed and bonded with an appropriate pressure to substantially A laminated display panel having a large adhesion area and good thermal conductivity can be obtained.
[0031]
On the other hand, after the display panel, the heat conductive sheet, and the heat sink are bonded together as described above, it is necessary to replace them if the display panel or the heat sink is defective. In the heat conductive sheet of the present invention, an aqueous solution containing a surfactant such as carboxylate, sulfonate, sulfate ester salt, isopropyl alcohol, ethanol, etc. in the pores arranged on the surface and inside of the adhesive surface layer By impregnating this solvent, the adhesive force to the display panel and the heat sink can be reduced, and repair can be easily performed. The aqueous solution concentration of the surfactant is preferably 5 to 30%. If it is less than 5, the effect of reducing the adhesive strength may not be sufficiently obtained. If it exceeds 30, impregnation into the pores may be difficult.
[0032]
【Example】
The present invention will be described more specifically with reference to examples.
Example 1
Aluminum hydroxide (H-32, Showa Denko KK) with respect to 100 parts of resin component of an emulsion in which an acrylic copolymer is dispersed in water (Pegard 851 manufactured by High Pressure Gas Industry Co., Ltd .; resin component 55%). Was applied onto a PET separator with a doctor blade and dried to obtain a sheet-like heat conductive substrate having a thickness of 950 μm. On the other hand, the viscosity of an emulsion in which an acrylic copolymer is dispersed in water (on the other hand, AE-150 manufactured by Yushi Kogyo Co., Ltd .; resin component 50%) is adjusted to 1200 cps by adding water, and the mixing ratio with air is adjusted. The volume ratio of 1: 1 was mixed for 1 hour with an Oaks mixer. This mixture was applied onto a PET separator with a doctor blade and dried to obtain an adhesive surface layer having a thickness of 50 μm. This adhesive surface layer had continuous pores having an average diameter of 30 μm and a porosity of 10%. Next, the adhesive surface layer was laminated on one side of the heat conductive substrate through a laminator roll to prepare a heat conductive sheet.
[0033]
(Example 2)
A heat conductive sheet was prepared in the same manner as in Example 1 except that the thickness of the heat conductive substrate was 900 μm and the adhesive surface layer was laminated on both surfaces of the heat conductive substrate.
(Example 3)
As the adhesive surface layer, except that a mixture obtained by adding 10 parts of aluminum hydroxide (H-32, manufactured by Showa Denko KK) as a heat conductive filler to 100 parts of the resin component of the emulsion was used as an acrylic copolymer emulsion. Produced the heat conductive sheet in the same manner as in Example 1.
[0034]
(Comparative Example 1)
A heat conductive sheet was obtained in the same manner as in Example 1 except that the thickness of the heat conductive substrate was 1000 μm and the adhesive surface layer was not laminated.
(Comparative Example 2)
A heat conductive sheet was prepared in the same manner as in Example 1 except that the adhesive surface layer was molded without mixing air into the acrylic copolymer emulsion. The adhesive surface layer of the obtained heat conductive sheet was free of pores as described above.
(Comparative Example 3)
The same procedure as in Example 1 was performed except that 3 parts of baking soda as a chemical foaming agent was added to 100 parts of the resin component to the acrylic copolymer emulsion, and the adhesive surface layer was formed without mixing air. A heat conductive sheet was produced.
[0035]
(Evaluation methods)
The characteristic evaluation of the heat conductive sheet of each Example of this invention and a comparative example was performed with the following evaluation methods, and the evaluation result was put together in Table 1 and shown. In addition, these evaluation methods show an example of the method for showing the effect of this invention.
1. Evaluation of Adhesion Ratio The adhesion ratio represents the degree of entrainment of bubbles when the heat conductive sheet is attached to a display panel or a heat sink. The test sample is affixed to the aluminum plate while bending the surface of the heat conductive sheet of each example and comparative example where the adhesive surface layer is not laminated (only one surface of the adhesive surface layer of Example 2) so that air does not enter. After reciprocating once with a 2 kg roller and pressing it, a glass plate 210 mm long, 300 mm wide and 5 mm thick is gently placed on the adhesive surface layer of the heat conductive sheet and cured at 23 ° C. for 72 hours. did. From the upper part of the glass surface of the test sample, a digital photograph of the pasting surface was taken, and the adhesion ratio was calculated from the number of image dots obtained by image processing.
[0036]
2. Thermal conductivity Thermal conductivity represents the thermal conductivity of the entire thermal conductive sheet. The test sample of the thermal conductivity test was a heat conductive sheet adjusted to a 2 cm × 3 cm rectangle, interposed between the heater block and the heat dissipation block, pressurized at a pressure of 20 g / cm 2 for 30 minutes, and then released. . Subsequently, after applying the heat transfer to the heater block for 4 minutes at a heat transfer amount of 5 W, the temperature difference between the heater block and the heat dissipation block is measured, and the product of the heat transfer amount and the thickness of the sample is the product of the heat transfer area and the temperature difference. Calculated by dividing by value.
[0037]
3. Adhesive retention strength Adhesive retention strength represents the degree of fixation stability when a heat conductive sheet is attached to a display panel or a heat sink. The test sample of the adhesion holding force was obtained in the same manner as the test sample of the adhesion ratio. The measurement method is that the prepared sample aluminum plate and glass plate are sheared in the plane direction with a force of 200 gf and attached to a jig and suspended in a 120 ° C. gear oven until both peel and fall. Is measured. In this adhesion retention test, the measurement was terminated in 500 hours for a sample that did not drop after 500 hours.
[0038]
4). Repairability Repairability represents the ease of removing each of the heat conductive sheets after they are attached to a display panel or a heat sink. The test sample for repairability was obtained in the same manner as the test sample for the adhesion ratio. The measurement method is to place the prepared sample so that it is fully immersed in a 10% aqueous solution containing a linear alkylbenzene sulfonate as a surfactant, take it out after standing for 24 hours, and point the tip like a flat plate like a screwdriver. This is a measure of the ease with which the display panel and the heat sink are removed using the jig. In this repair test, those that can be easily removed without deforming or destroying the display panel and the heat sink, and those that can be easily removed without deforming or destroying the display panel and the heat sink. X.
[0039]
[Table 1]
All the heat conductive sheets of the examples of the present invention had a good adhesion ratio with the aluminum plate, and all of the heat conductivity, the adhesion holding force and the repairability were good. On the other hand, in the heat conductive sheet of Comparative Example 1 having no adhesive surface layer, the adhesion ratio and repairability are insufficient, and Comparative Example 2 in which the adhesive surface layer does not have pores and the comparison in which the pores are closed cells. In the heat conductive sheet of Example 3, all of the adhesion ratio, the thermal conductivity, and the repairability were insufficient, and Comparative Example 3 was inferior in the adhesion holding power.
[0041]
【The invention's effect】
The heat conductive sheet of the present invention is provided with an adhesive surface layer having pores having a continuous structure with a small-diameter tube, so that when the heat sink is fixed to the back surface of the display panel, the heat conductive sheet is caught in these interfaces. By effectively letting out the bubbles, the adhesion area can be expanded, and as a result, the thermal conductivity and adhesion retention can be improved. In addition, by impregnating pores arranged on the surface and inside of the adhesive surface layer with an aqueous solution containing a surfactant such as carboxylate, sulfonate, sulfate ester salt, or a solvent such as isopropyl alcohol or ethanol. The repair property can be improved by reducing the adhesive force to the display panel and the heat sink.
Claims (4)
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| JP2003174592A JP4531354B2 (en) | 2002-10-29 | 2003-06-19 | Heat conduction sheet |
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| KR100821382B1 (en) * | 2005-01-21 | 2008-04-10 | 엘지전자 주식회사 | Plasma Display Apparatus |
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| JP5390778B2 (en) * | 2008-03-11 | 2014-01-15 | 出光興産株式会社 | Organic electroluminescence panel |
| KR101588576B1 (en) | 2008-07-10 | 2016-01-26 | 가부시키가이샤 한도오따이 에네루기 켄큐쇼 | Light emitting device and electronic device |
| TWI587734B (en) | 2009-03-26 | 2017-06-11 | 精工愛普生股份有限公司 | Organic el apparatus, method of manufacturing organic el apparatus, electronic apparatus |
| JP5853311B2 (en) * | 2011-10-31 | 2016-02-09 | 株式会社Ｊｏｌｅｄ | Display device and manufacturing method of display device |
| JP5609941B2 (en) * | 2012-09-26 | 2014-10-22 | セイコーエプソン株式会社 | Display device and electronic device |
| JP2016151006A (en) * | 2015-02-19 | 2016-08-22 | Dic株式会社 | Adhesive sheet, manufacturing method therefor and electronic device |
| JP2016155950A (en) * | 2015-02-25 | 2016-09-01 | Dic株式会社 | Tacky-adhesive sheet, production method thereof, and electronic equipment |
| CN107828350A (en) * | 2017-12-15 | 2018-03-23 | 常熟市长江胶带有限公司 | One kind radiating damping solar cell module fixation adhesive tape |
| US12060261B2 (en) * | 2019-11-06 | 2024-08-13 | Bvw Holding Ag | Extremal microstructured surfaces |
| KR102371499B1 (en) * | 2020-03-31 | 2022-03-07 | 주식회사 아이엠씨 | Heat-radiating foam tape |
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