WO2016114317A1 - 接着層形成用の組成物、接着層、接着層の製造方法、複合材、シート、放熱部材、電子デバイス、バッテリー、キャパシタ、自動車用部品および機械機構部品 - Google Patents
接着層形成用の組成物、接着層、接着層の製造方法、複合材、シート、放熱部材、電子デバイス、バッテリー、キャパシタ、自動車用部品および機械機構部品 Download PDFInfo
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- WO2016114317A1 WO2016114317A1 PCT/JP2016/050872 JP2016050872W WO2016114317A1 WO 2016114317 A1 WO2016114317 A1 WO 2016114317A1 JP 2016050872 W JP2016050872 W JP 2016050872W WO 2016114317 A1 WO2016114317 A1 WO 2016114317A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- adhesive layer
- sheet
- polyvinyl acetal
- acetal resin
- composition
- Prior art date
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- XBDQKXXYIPTUBI-UHFFFAOYSA-M Propionate Chemical compound CCC([O-])=O XBDQKXXYIPTUBI-UHFFFAOYSA-M 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- QYKIQEUNHZKYBP-UHFFFAOYSA-N Vinyl ether Chemical class C=COC=C QYKIQEUNHZKYBP-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- KXKVLQRXCPHEJC-UHFFFAOYSA-N acetic acid trimethyl ester Natural products COC(C)=O KXKVLQRXCPHEJC-UHFFFAOYSA-N 0.000 description 1
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 1
- 239000005456 alcohol based solvent Substances 0.000 description 1
- 125000003158 alcohol group Chemical group 0.000 description 1
- 150000001299 aldehydes Chemical class 0.000 description 1
- 150000001338 aliphatic hydrocarbons Chemical class 0.000 description 1
- XYLMUPLGERFSHI-UHFFFAOYSA-N alpha-Methylstyrene Chemical compound CC(=C)C1=CC=CC=C1 XYLMUPLGERFSHI-UHFFFAOYSA-N 0.000 description 1
- WUOACPNHFRMFPN-UHFFFAOYSA-N alpha-terpineol Chemical compound CC1=CCC(C(C)(C)O)CC1 WUOACPNHFRMFPN-UHFFFAOYSA-N 0.000 description 1
- 229920005603 alternating copolymer Polymers 0.000 description 1
- 150000001408 amides Chemical class 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 150000004945 aromatic hydrocarbons Chemical class 0.000 description 1
- 239000003849 aromatic solvent Substances 0.000 description 1
- 235000019445 benzyl alcohol Nutrition 0.000 description 1
- 229920001400 block copolymer Polymers 0.000 description 1
- 239000010974 bronze Substances 0.000 description 1
- 238000003763 carbonization Methods 0.000 description 1
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 1
- 150000008280 chlorinated hydrocarbons Chemical class 0.000 description 1
- YOCUPQPZWBBYIX-UHFFFAOYSA-N copper nickel Chemical compound [Ni].[Cu] YOCUPQPZWBBYIX-UHFFFAOYSA-N 0.000 description 1
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 1
- 125000000113 cyclohexyl group Chemical group [H]C1([H])C([H])([H])C([H])([H])C([H])(*)C([H])([H])C1([H])[H] 0.000 description 1
- SQIFACVGCPWBQZ-UHFFFAOYSA-N delta-terpineol Natural products CC(C)(O)C1CCC(=C)CC1 SQIFACVGCPWBQZ-UHFFFAOYSA-N 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 125000003438 dodecyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 239000003759 ester based solvent Substances 0.000 description 1
- UIWXSTHGICQLQT-UHFFFAOYSA-N ethenyl propanoate Chemical compound CCC(=O)OC=C UIWXSTHGICQLQT-UHFFFAOYSA-N 0.000 description 1
- 239000004210 ether based solvent Substances 0.000 description 1
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 1
- 230000005496 eutectics Effects 0.000 description 1
- XUCNUKMRBVNAPB-UHFFFAOYSA-N fluoroethene Chemical compound FC=C XUCNUKMRBVNAPB-UHFFFAOYSA-N 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052736 halogen Inorganic materials 0.000 description 1
- 150000002367 halogens Chemical class 0.000 description 1
- 125000001976 hemiacetal group Chemical group 0.000 description 1
- 150000002430 hydrocarbons Chemical group 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 229910000765 intermetallic Inorganic materials 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 125000000959 isobutyl group Chemical group [H]C([H])([H])C([H])(C([H])([H])[H])C([H])([H])* 0.000 description 1
- 229960004592 isopropanol Drugs 0.000 description 1
- 239000005453 ketone based solvent Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 150000002736 metal compounds Chemical class 0.000 description 1
- 229910052987 metal hydride Inorganic materials 0.000 description 1
- 229910000000 metal hydroxide Inorganic materials 0.000 description 1
- 150000004692 metal hydroxides Chemical class 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- XJRBAMWJDBPFIM-UHFFFAOYSA-N methyl vinyl ether Chemical compound COC=C XJRBAMWJDBPFIM-UHFFFAOYSA-N 0.000 description 1
- 239000003607 modifier Substances 0.000 description 1
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 1
- 125000004108 n-butyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 150000002825 nitriles Chemical class 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 125000001436 propyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- UMJSCPRVCHMLSP-UHFFFAOYSA-N pyridine Natural products COC1=CC=CN=C1 UMJSCPRVCHMLSP-UHFFFAOYSA-N 0.000 description 1
- HNJBEVLQSNELDL-UHFFFAOYSA-N pyrrolidin-2-one Chemical compound O=C1CCCN1 HNJBEVLQSNELDL-UHFFFAOYSA-N 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 229920005604 random copolymer Polymers 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 150000003384 small molecules Chemical class 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- MNCGMVDMOKPCSQ-UHFFFAOYSA-M sodium;2-phenylethenesulfonate Chemical compound [Na+].[O-]S(=O)(=O)C=CC1=CC=CC=C1 MNCGMVDMOKPCSQ-UHFFFAOYSA-M 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 125000004079 stearyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 229940116411 terpineol Drugs 0.000 description 1
- ISXSCDLOGDJUNJ-UHFFFAOYSA-N tert-butyl prop-2-enoate Chemical compound CC(C)(C)OC(=O)C=C ISXSCDLOGDJUNJ-UHFFFAOYSA-N 0.000 description 1
- 229920001567 vinyl ester resin Polymers 0.000 description 1
- 229910052724 xenon Inorganic materials 0.000 description 1
- FHNFHKCVQCLJFQ-UHFFFAOYSA-N xenon atom Chemical compound [Xe] FHNFHKCVQCLJFQ-UHFFFAOYSA-N 0.000 description 1
- 239000004711 α-olefin Substances 0.000 description 1
- PAPBSGBWRJIAAV-UHFFFAOYSA-N ε-Caprolactone Chemical class O=C1CCCCCO1 PAPBSGBWRJIAAV-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J129/00—Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Adhesives based on hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Adhesives based on derivatives of such polymers
- C09J129/14—Homopolymers or copolymers of acetals or ketals obtained by polymerisation of unsaturated acetals or ketals or by after-treatment of polymers of unsaturated alcohols
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
- C09J11/02—Non-macromolecular additives
- C09J11/06—Non-macromolecular additives organic
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J201/00—Adhesives based on unspecified macromolecular compounds
- C09J201/02—Adhesives based on unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups
- C09J201/06—Adhesives based on unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups containing oxygen atoms
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
- H01G11/04—Hybrid capacitors
- H01G11/06—Hybrid capacitors with one of the electrodes allowing ions to be reversibly doped thereinto, e.g. lithium ion capacitors [LIC]
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
- H01G11/14—Arrangements or processes for adjusting or protecting hybrid or EDL capacitors
- H01G11/18—Arrangements or processes for adjusting or protecting hybrid or EDL capacitors against thermal overloads, e.g. heating, cooling or ventilating
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
- H01G11/78—Cases; Housings; Encapsulations; Mountings
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/34—Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements
- H01L23/36—Selection of materials, or shaping, to facilitate cooling or heating, e.g. heatsinks
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/34—Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements
- H01L23/36—Selection of materials, or shaping, to facilitate cooling or heating, e.g. heatsinks
- H01L23/373—Cooling facilitated by selection of materials for the device or materials for thermal expansion adaptation, e.g. carbon
- H01L23/3735—Laminates or multilayers, e.g. direct bond copper ceramic substrates
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/36—Selection of substances as active materials, active masses, active liquids
- H01M4/58—Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
- H01M4/583—Carbonaceous material, e.g. graphite-intercalation compounds or CFx
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/10—Batteries
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/16—Capacitors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/08—Cars
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
- H01G11/10—Multiple hybrid or EDL capacitors, e.g. arrays or modules
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
Definitions
- the present invention relates to a composition for forming an adhesive layer, an adhesive layer, a method for producing the adhesive layer, a composite material, a sheet, a heat radiating member, an electronic device, a battery, a capacitor, an automotive component, and a mechanical mechanism component.
- Patent Document 1 a laminate in which a graphite sheet and a metal plate are bonded with an adhesive layer formed from a composition containing a polyvinyl acetal resin is disclosed.
- LED Light Emitting Diode
- IGBTs Insulated Gate Bipolar Transistors
- the conventionally known adhesive layer used for the heat dissipation member is assumed to have a heat resistant temperature of 100 ° C. or lower for the purpose of heat dissipation of a semiconductor device (IC chip such as a CPU or memory) using a silicon semiconductor.
- Conventionally known adhesive layers used for heat dissipation members have room for improvement in terms of adhesion at high temperatures.
- the present invention has been made in view of such problems, and an object of the present invention is to provide a composition capable of forming an adhesive layer having excellent adhesion to an adherend even at high temperatures (about 120 ° C.).
- a configuration example of the present invention is as follows.
- a composition for forming an adhesive layer comprising a polyvinyl acetal resin and a compound having an oxazoline group.
- the polyvinyl acetal resin includes structural units A, B, and C.
- R is independently hydrogen or alkyl.
- the polyvinyl acetal resin further includes a structural unit D.
- R 1 is independently hydrogen or alkyl having 1 to 5 carbon atoms.
- R in the structural unit A is hydrogen or alkyl having 1 to 3 carbon atoms.
- Step (1) Step of forming a layer containing a polyvinyl acetal resin and a compound having an oxazoline group
- Step (2) Step of heating the layer obtained in Step (1)
- Graphite sheet, carbon fiber, One type of carbon material selected from the group consisting of carbon nanotubes and diamond, or at least two types of carbon materials selected from the group were bonded via the adhesive layer described in [6] or [7].
- Composite material. [10] A sheet in which at least one carbon material selected from the group consisting of a graphite sheet, carbon fiber, carbon nanotube, and diamond and a metal sheet are bonded via the adhesive layer according to [6] or [7]. .
- a heat dissipation member including at least one selected from the composite material according to [9] and the sheet according to [10].
- An electronic device comprising at least one selected from the composite material according to [9], the sheet according to [10], and the heat dissipation member according to [11].
- a battery comprising at least one selected from the composite material according to [9], the sheet according to [10], and the heat dissipation member according to [11].
- a capacitor including at least one selected from the composite material according to [9], the sheet according to [10], and the heat dissipation member according to [11].
- An automotive part including at least one selected from the composite material according to [9], the sheet according to [10], and the heat radiating member according to [11].
- a mechanical mechanism component including at least one selected from the composite material according to [9], the sheet according to [10], and the heat radiating member according to [11].
- an adhesive layer having excellent adhesion to an adherend is formed even at a high temperature, specifically at a temperature of about 120 ° C. or more.
- a composition that can be provided can be provided.
- an adhesive layer excellent in adhesion to an adherend particularly a metal material such as a metal sheet, or a carbon material such as a graphite sheet can be formed.
- the composition of the present invention has a remarkably superior effect over the conventional composition, and has a synergistic effect exceeding the additive effect of the polyvinyl acetal resin and the compound having an oxazoline group.
- composition for forming an adhesive layer of the present invention includes a polyvinyl acetal resin and a compound having an oxazoline group. Since the composition of this invention has the above effects, it can also be called an adhesive.
- the composition of the present invention may be a one-component (one-component) composition containing a polyvinyl acetal resin and a compound having an oxazoline group, and includes a component containing a polyvinyl acetal resin and a compound having an oxazoline group. It may be a two-component (two-component) composition with components. Whether it is a one-component type or a two-component type may be appropriately selected according to desired requirements and the like. For example, it may be a one-component type for easily forming an adhesive layer, storage stability, etc. In consideration of this, a two-component type may be used.
- the polyvinyl acetal resin is not particularly limited, but an adhesive layer having excellent toughness, heat resistance and impact resistance, and excellent adhesion to adherends, particularly metal materials such as metal sheets and carbon materials such as graphite sheets, can be obtained. From the point of being obtained, it is preferable that it is resin containing the following structural units A, B, and C.
- the structural unit A is a structural unit having an acetal moiety, and can be formed, for example, by a reaction between a vinyl alcohol unit and an aldehyde (R-CHO).
- R in the structural unit A is independently hydrogen or alkyl. If the R is a bulky group (for example, a hydrocarbon group having a large number of carbon atoms), the softening point of the polyvinyl acetal resin may be lowered. Further, the polyvinyl acetal resin in which R is a bulky group has high solubility in a solvent, but may be inferior in chemical resistance. Therefore, R is preferably hydrogen or alkyl having 1 to 5 carbon atoms, more preferably hydrogen or alkyl having 1 to 3 carbon atoms from the viewpoint of the toughness of the resulting adhesive layer, and is preferably hydrogen or propyl. More preferably, hydrogen is particularly preferable from the viewpoint of heat resistance.
- the polyvinyl acetal resin contains the following constitutional unit D in addition to the constitutional units A to C, and has excellent heat resistance and adhesion at high temperatures to a metal material such as a metal sheet and a carbon material such as a graphite sheet. It is preferable from the viewpoint that a layer can be obtained.
- R 1 is independently hydrogen or alkyl having 1 to 5 carbon atoms, preferably hydrogen or alkyl having 1 to 3 carbon atoms, more preferably hydrogen.
- the total content of the structural units A, B, C, and D in the polyvinyl acetal resin is preferably 80 to 100 mol% with respect to all the structural units of the resin.
- Other structural units that can be included in the polyvinyl acetal resin include vinyl acetal chain units other than the structural unit A (structural units in which R in the structural unit A is other than hydrogen or alkyl), the following intermolecular acetal units, and the following hemi Examples include acetal units.
- the content of vinyl acetal chain units other than the structural unit A is preferably less than 5 mol% with respect to all the structural units of the polyvinyl acetal resin.
- the structural units A to D may be regularly arranged (block copolymer, alternating copolymer, etc.) or randomly arranged (random copolymer). It is preferable that they are arranged.
- Each constituent unit in the polyvinyl acetal resin has a constituent unit A content of 49.9 to 80 mol% and a constituent unit B content of 0.1 to 49.9 mol% with respect to all constituent units of the resin.
- the content of the structural unit C is 0.1 to 49.9 mol%
- the content of the structural unit D is 0 to 49.9 mol%.
- the content of the structural unit A is 49.9 to 80 mol% and the content of the structural unit B is 1 to 30 mol% with respect to all the structural units of the polyvinyl acetal resin.
- the content is 1 to 30 mol%
- the content of the structural unit D is 1 to 30 mol%.
- the content of the structural unit A is preferably 49.9 mol% or more.
- the content of the structural unit B is 0.1 mol% or more because the solubility of the polyvinyl acetal resin in the solvent is improved. Moreover, it is preferable for the content of the structural unit B to be 49.9 mol% or less because the chemical resistance, flexibility, wear resistance and mechanical strength of the polyvinyl acetal resin are unlikely to decrease.
- the structural unit C has a content of 49.9 mol in terms of solubility of the polyvinyl acetal resin in a solvent and adhesion of the obtained adhesive layer to a metal material such as a metal sheet or a carbon material such as a graphite sheet. % Or less is preferable. Further, in the production of the polyvinyl acetal resin, when the polyvinyl alcohol chain is acetalized, the structural unit B and the structural unit C are in an equilibrium relationship, and therefore the content of the structural unit C may be 0.1 mol% or more. preferable.
- the content of the structural unit D is preferably in the above range from the viewpoint that an adhesive layer excellent in adhesion to a metal material such as a metal sheet or a carbon material such as a graphite sheet can be obtained.
- the content of each of the structural units A to C in the polyvinyl acetal resin can be measured according to JIS K 6728 or JIS K 6729.
- the content rate of the structural unit D in a polyvinyl acetal resin can be measured by the method described below.
- the polyvinyl acetal resin is heated at 80 ° C. for 2 hours in a 1 mol / l sodium hydroxide aqueous solution. By this operation, sodium is added to the carboxyl group, and a polymer having —COONa is obtained. Excess sodium hydroxide is extracted from the polymer and then dehydrated and dried. Thereafter, carbonization is performed and atomic absorption analysis is performed, and the amount of sodium added is determined and quantified.
- the structural unit B (vinyl acetate chain)
- the structural unit D measured according to JIS K 6728 or JIS K6729 is used.
- the content rate of the structural unit D determined is subtracted from the content rate, and the content rate of the structural unit B is corrected.
- the weight average molecular weight of the polyvinyl acetal resin is preferably 5000 to 300,000, and more preferably 10,000 to 150,000. Use of a polyvinyl acetal resin having a weight average molecular weight within the above range is preferable because the adhesive layer, composite material, sheet and heat dissipation member of the present invention can be easily produced.
- the weight average molecular weight of the polyvinyl acetal resin can be measured by gel permeation chromatography (GPC). Specific measurement conditions are as follows. Detector: 830-RI (manufactured by JASCO Corporation) Oven: NFL-700M manufactured by Nishio Kogyo Co., Ltd. Separation column: Shodex KF-805L x 2 Pump: PU-980 (manufactured by JASCO Corporation) Temperature: 30 ° C Carrier: Tetrahydrofuran Standard sample: Polystyrene
- the Ostwald viscosity of the polyvinyl acetal resin is preferably 1 to 100 mPa ⁇ s.
- a polyvinyl acetal resin having an Ostwald viscosity in the above range is used, the adhesive layer, composite material, sheet and heat dissipation member of the present invention can be easily produced, and the composite material, sheet and heat dissipation member of the present invention having excellent toughness can be obtained.
- the Ostwald viscosity can be measured using an Ostwald-Cannon Fenske Viscometer at 20 ° C. using a solution obtained by dissolving 5 g of polyvinyl acetal resin in 100 ml of dichloroethane.
- polyvinyl acetal resin examples include polyvinyl butyral, polyvinyl formal, polyvinyl acetoacetal, and derivatives thereof, and adhesion to adherends, particularly metal materials such as metal sheets and carbon materials such as graphite sheets.
- Polyvinyl formal is preferable from the viewpoint of obtaining an adhesive layer excellent in heat resistance and heat resistance.
- the polyvinyl acetal resin may be obtained by synthesis or may be a commercially available product.
- the method for synthesizing the resin containing the structural units A, B and C is not particularly limited, and examples thereof include the method described in JP-A-2009-298833.
- the method for synthesizing the resin containing the structural units A, B, C and D is not particularly limited, and examples thereof include a method described in JP 2010-202862 A.
- polyvinyl acetal resins examples include vinyl formal C, vinylec K, and vinylec K (trade name, manufactured by JNC Corporation), and polyvinyl butyral, denkabutyral 3000-K (trade name, electrochemical industry ( Etc.).
- the resin may be used alone, or two or more resins having different types of structural units, the order of bonding, the number of bonds, and the like may be used.
- the compound having an oxazoline group (hereinafter also referred to as “oxazoline compound”) used in the present invention is not particularly limited as long as it has an oxazoline group, and may be a low molecular compound or a polymer.
- a polymer having an oxazoline group is preferable from the viewpoint of obtaining an adhesive layer excellent in adhesion to an adherend.
- the adhesive layer is provided between two or more members, when a by-product is generated in such an adhesive layer, the by-product usually cannot be removed from the adhesive layer to the outside. In this case, if a high temperature of 100 ° C. or higher is applied to the adhesive layer in which the by-product is generated, the adhesive property of the adhesive layer may be reduced or the shape of the adhesive layer may be changed. However, even if the oxazoline compound reacts with the polyvinyl acetal resin, by-products such as water tend not to be generated, and therefore, the use of the compound makes it difficult to lower the adhesive property even at high temperatures. An adhesive layer having excellent heat resistance can be obtained. On the other hand, since an epoxy compound or the like tends to generate a by-product such as water by the reaction, it is preferable not to use such a compound in the present invention.
- Examples of the low molecular weight compound having an oxazoline group include 2-vinyl-2-oxazoline, 2-vinyl-4-methyl-2-oxazoline, 2-vinyl-5-methyl-2-oxazoline, 2-isopropenyl- Oxazoline groups in the molecule such as 2-oxazoline, 2-isopropenyl-4-methyl-2-oxazoline, 2-isopropenyl-5-methyl-2-oxazoline, 2-isopropenyl-5-ethyl-2-oxazoline Compound having one; 2,2′-bis (2-oxazoline), 2,2′-methylenebis (2-oxazoline), 2,2′-ethylenebis (2-oxazoline), 2,2′-trimethylenebis (2-oxazoline), 2,2'-tetramethylenebis (2-oxazoline), 2,2'-hexamethylenebis (2-oxazoline) 2,2′-octamethylenebis (2-oxazoline), 2,2′-ethylenebis (4,4′-
- Examples of the polymer having an oxazoline group include a polymer obtained by using a monomer having an oxazoline group.
- the polymer may be a polymer of a monomer having an oxazoline group, or may be a copolymer obtained by polymerizing the monomer and another monomer copolymerizable with the monomer.
- the monomer used may be a single monomer or two or more monomers.
- Examples of the monomer having an oxazoline group include the same compounds as those exemplified as the low molecular compound having the oxazoline group, and among these, a compound having one oxazoline group in the molecule is preferable.
- Examples of other monomers copolymerizable with the monomer having an oxazoline group include methyl (meth) acrylate, ethyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, (meth ) T-butyl acrylate, cyclohexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, methoxypolyethylene glycol (meth) acrylate, lauryl (meth) acrylate, stearyl (meth) acrylate, (meth) 2-hydroxyethyl acrylate, 2-hydroxypropyl (meth) acrylate, monoesterified product of (meth) acrylic acid and polyethylene glycol, 2-aminoethyl (meth) acrylate and salts thereof, (meth) A modified caprolactone of acrylic acid, (meth) acrylic acid-2, , 6,6-tetra
- the amount of the monomer having an oxazoline group in the copolymer is not particularly limited, but is preferably 5% by mass or more, more preferably 5 to 90% by mass, and further preferably 10 to 10% by mass with respect to all monomers. 80% by mass, particularly preferably 30 to 60% by mass.
- oxazoline compound a compound obtained by synthesis by a conventionally known method may be used, or a commercially available product may be used.
- commercially available polymers having an oxazoline group include Epocros K series, Epocros WS series, and Epocros RPS manufactured by Nippon Shokubai Co., Ltd., and specifically, Epocros WS-500 and Epocros RPS-1005. Is mentioned.
- commercially available low molecular compounds having an oxazoline group include 2,2 ′-(1,3-phenylene) bis (2-oxazoline) manufactured by Mikuni Pharmaceutical Co., Ltd.
- the content of the oxazoline compound is preferably relative to 1 part by mass of the polyvinyl acetal resin from the viewpoint of obtaining an adhesive layer having a good balance between adhesion to an adherend, particularly adhesion at high temperatures and heat resistance.
- the composition of the present invention is such that an adhesive layer having an excellent balance between adhesion to the adherend, particularly adhesion at high temperatures, heat resistance and heat dissipation can be obtained.
- it is more preferably 0.05 to 0.5 parts by mass.
- An oxazoline compound may be used independently and may use 2 or more types.
- the composition of the present invention may or may not contain a solvent, but preferably contains a solvent from the viewpoint of ease of formation of the adhesive layer.
- the solvent is preferably one that can dissolve the polyvinyl acetal resin and the oxazoline compound.
- examples of such solvents include alcohol solvents such as methanol, ethanol, n-propanol, iso-propanol, 1-methoxy-2-propanol, n-butanol, sec-butanol, n-octanol, diacetone alcohol, and benzyl alcohol.
- Cellosolv solvents such as methyl cellosolve, ethyl cellosolve, butyl cellosolve; ketone solvents such as acetone, methyl ethyl ketone, cyclopentanone, cyclohexanone, isophorone; N, N-dimethylacetamide, N, N-dimethylformamide, 1-methyl-2 -Amide solvents such as pyrrolidone; Ester solvents such as methyl acetate and ethyl acetate; Ether solvents such as dioxane and tetrahydrofuran; Chlorinated hydrocarbon solvents such as methylene chloride and chloroform ; Dimethylsulfoxide; acetic acid; terpineol; butyl carbitol; toluene, aromatic solvents such as pyridine organic solvent or water, such as butyl carbitol acetate and the like. These solvents may be used alone or in combination of two or more.
- the solvent is used in an amount of preferably 500 to 5000 parts by mass, more preferably 700 to 1500 parts by mass with respect to 100 parts by mass of the polyvinyl acetal resin in the composition, and relative to 100 parts by mass of the oxazoline compound in the composition. It is preferably used in an amount of 1000 to 500,000 parts by mass, more preferably 2800 to 60000 parts by mass from the viewpoint of obtaining a composition that hardly causes precipitation and is excellent in storage stability.
- additives such as a stabilizer and a modifier
- a commercially available additive can be used.
- other resin can also be added to the composition of this invention in the range which does not impair the characteristic of polyvinyl acetal resin.
- additives may be used alone or in combination of two or more.
- the additive for example, when the resin forming the adhesive layer is deteriorated by contact with a metal, a copper damage inhibitor or a metal deactivator as described in JP-A-5-48265 is used.
- a copper damage inhibitor or a metal deactivator as described in JP-A-5-48265 is used.
- the addition of a silane coupling agent is preferred in order to improve the adhesion between the thermally conductive filler and the polyvinyl acetal resin.
- silane coupling agent a silane coupling agent (trade name; S330, S510, S520, S530) manufactured by JNC Corporation is preferable.
- the addition amount of the silane coupling agent is preferably 1 to 10 mass with respect to 100 mass parts of the total amount of the resin contained in the composition of the present invention from the viewpoint that the adhesion to the metal sheet can be improved. Part.
- the polyvinyl acetal resin has been used for enameled wires for a long time, and is a resin that is difficult to deteriorate or deteriorate when contacted with a metal, but an adhesive layer obtained from the composition of the present invention.
- a copper damage inhibitor or a metal deactivator may be added to the composition.
- the addition amount of the copper damage inhibitor is preferably 0 with respect to 100 parts by mass of the total amount of the resin contained in the composition of the present invention from the viewpoint of preventing the deterioration of the resin in the part in contact with the metal of the adhesive layer. 1 to 3 parts by mass.
- the composition of the present invention may contain a small amount of a thermally conductive filler for the purpose of improving the thermal conductivity, but adding a large amount of the thermally conductive filler may reduce the adhesive performance. When adding, it is necessary to pay attention to the balance between the addition amount and the adhesion performance.
- the heat conductive filler is not particularly limited, but a metal or metal compound-containing filler such as metal powder, metal oxide powder, metal nitride powder, metal hydroxide powder, metal oxynitride powder and metal carbide powder, and Examples include fillers containing carbon materials. These heat conductive fillers may be used independently and may use 2 or more types.
- thermally conductive filler a commercially available product having an average diameter or shape in a desired range may be used as it is, or a commercially available product that has been crushed, classified, heated, etc. so that the average diameter or shape is in a desired range is used. May be.
- a preferable blending amount of the heat conductive filler is 1 to 20% by mass with respect to 100% by mass of the composition of the present invention.
- the composition of this invention can be obtained by mixing a polyvinyl acetal resin, an oxazoline compound, and the said solvent and additive as needed.
- the composition of the present invention is a one-component composition
- the composition is preferably a one-component composition prepared by dissolving a polyvinyl acetal resin and an oxazoline compound in a solvent.
- the composition of the present invention is a two-component composition (including the above-mentioned additives if necessary)
- the composition includes one liquid obtained by dissolving a polyvinyl acetal resin in a solvent, and an oxazoline compound as a solvent.
- a two-component composition with one solution dissolved is preferable (including the additives as necessary).
- the additive that is blended as necessary may be blended in either one of the liquids or in both liquids.
- the adhesive layer of the present invention is a layer obtained using a polyvinyl acetal resin and an oxazoline compound, or a layer obtained using the composition of the present invention.
- Such an adhesive layer has a high temperature, specifically, a temperature of about 120 ° C. or more, and even if the thickness is small, an adherend, particularly a metal material such as a metal sheet or a carbon material such as a graphite sheet. Because of its excellent adhesive properties, using such an adhesive layer, it has excellent heat resistance, durability and heat dissipation characteristics, and can be reduced in weight and size, heat dissipation members, and electronic devices, batteries, capacitors, automobiles Parts and machine mechanism parts can be obtained.
- the thickness of the adhesive layer is preferably as thin as possible from the viewpoint that the thermal resistance can be reduced if it has a thickness that can adhere the adherend, more preferably 30 ⁇ m or less, and even more preferably 10 ⁇ m or less, Particularly preferably, it is 5 ⁇ m or less. Since the adhesive layer of the present invention contains a polyvinyl acetal resin and an oxazoline compound, even if the thickness of the adhesive layer is 1 ⁇ m or less, an adherend, particularly a metal material such as a metal sheet, or a carbon material such as a graphite sheet Can be glued.
- Step (1) Step of forming a layer containing a polyvinyl acetal resin and an oxazoline compound
- Step (1) is a step of forming a layer containing a polyvinyl acetal resin and an oxazoline compound.
- this step (1) it is preferable to use the composition of the present invention, particularly the one-component composition or the two-component composition.
- the one-component composition or the two-component composition is applied to an adherend by a conventionally known method and, if necessary, preliminarily dried.
- the process of forming the layer containing an oxazoline compound is mentioned.
- two liquids may be mixed in advance and then applied onto the adherend, and one liquid may be applied onto the adherend, One liquid may be applied.
- one liquid may be applied on the adherend and preliminarily dried, and then another liquid may be applied.
- an adhesive layer having excellent adhesion and heat resistance at high temperatures can be obtained.
- a layer containing a polyvinyl acetal resin and an oxazoline compound may be formed.
- the conditions for the preliminary drying are not particularly limited and may be appropriately selected depending on the composition to be used.
- the preliminary drying temperature is 60 to 120 ° C.
- the drying time is about 1 to 30 minutes. It is.
- Step (2) is a step of heating the layer obtained in step (1).
- An adhesive layer is obtained by this process.
- the heating temperature in the step (2) depends on the heat resistance temperature of the adherend, but is preferably 150 to 250 ° C., more preferably from the viewpoint of obtaining an adhesive layer having excellent adhesion at high temperatures. Is in the range of 170 to 220 ° C., and more preferably in the range of 200 to 220 ° C. from the viewpoint of obtaining an adhesive layer that is more excellent in heat resistance.
- the heating time in the step (2) is preferably 0.1 to 30 minutes, more preferably from the viewpoint of obtaining an adhesive layer having excellent adhesiveness, although it depends on the thickness of the obtained adhesive layer. Is preferably from 0.1 to 20 minutes.
- the thickness of the adhesive layer of the present invention is in the above-mentioned range, it is particularly preferable from the viewpoint that an adhesive layer excellent in heat resistance can be obtained with good economical efficiency. 1 to 3 minutes. According to the present invention, even with such a short heating time, an adhesive layer excellent in adhesiveness and further adhesiveness at high temperature can be obtained, and an adhesive layer excellent in heat resistance can be obtained.
- a member including the adhesive layer can be formed economically.
- Step (2) is preferably heated while applying pressure from the viewpoint of improving the adhesive strength with the adherend.
- the pressure at this time is not particularly limited, but is, for example, 5 to 100 MPa.
- the composite material of the present invention comprises one carbon material selected from the group consisting of graphite sheet, carbon fiber, carbon nanotube and diamond, or at least two carbon materials selected from the group, with the adhesive layer interposed therebetween. It is a composite material bonded together.
- the carbon material when a graphite sheet is used as the carbon material, at least two graphite sheets are bonded together via the adhesive layer.
- the laminated body is mentioned.
- the at least two graphite sheets may be the same sheet, or may be sheets having different thicknesses, shapes, materials, and the like.
- the adhesive layer may be present only on the adhesion surface of at least two fibers, and is present on the entire outer surface or inner and outer surfaces of at least two fibers. Also good.
- the composite material in which the adhesive layer is present on the entire outer surface or the entire inner and outer surfaces of at least two fibers include a composite material in which at least two fibers are dispersed in the adhesive layer.
- the at least two fibers may be the same fiber, or may be fibers having different shapes and materials. The case of using carbon nanotubes or diamond as the carbon material is the same as the case of using carbon fibers.
- carbon fiber or the like when a carbon fiber, carbon nanotube, or diamond (hereinafter also referred to as “carbon fiber or the like”) and a graphite sheet are used as the carbon material, the composite material in which at least two kinds of carbon materials are bonded is used.
- the composite material obtained contains at least two graphite sheets these sheets may be the same sheet, or may be sheets having different thicknesses, shapes, materials, and the like. The same applies to carbon fiber and the like.
- the composite material of the present invention is preferably a composite material including at least two graphite sheets.
- the graphite sheet has a large thermal conductivity, is light and flexible. Therefore, by using such a graphite sheet, a lightweight composite material having excellent heat dissipation characteristics can be obtained. For this reason, this composite material is used suitably as a heat radiating member, and is used suitably especially as a heat radiating member of the heat generating body which becomes high temperature.
- the graphite sheet is not particularly limited as long as it is a sheet made of graphite.
- those produced by the methods described in JP-A-61-275117 and JP-A-11-21117 may be used, Commercial products may be used.
- artificial graphite sheets (trade names) manufactured from synthetic resin sheets, eGRAF® SPREADERSSHIELD SS-1500 (manufactured by GrafTECH® International), Graffiti (manufactured by Kaneka Corp.), PGS graphite sheets (Panasonic Corp.)
- natural graphite sheet (trade name) manufactured from natural graphite include eGRAF SPREADERSHIELD SS-500 (manufactured by GrafTECH International).
- the thermal conductivity in the plane direction of the graphite sheet is preferably 250 to 2000 W / m ⁇ K, more preferably 500 to 2000 W / m ⁇ K.
- This thermal conductivity can be calculated by measuring the thermal diffusivity, specific heat and density with a laser flash or xenon flash thermal diffusivity measuring device, DSC and Archimedes method, respectively, and multiplying them.
- the thickness of the graphite sheet is not particularly limited.
- a thick layer is preferable, but it is more preferably 15 to 600 ⁇ m, further preferably 15 to 500 ⁇ m, and particularly preferably 15 to 300 ⁇ m. is there.
- seat in which the hole and the slit were provided in the part may be sufficient.
- the sheet of the present invention is a sheet in which at least one carbon material selected from the group consisting of a graphite sheet, carbon fiber, carbon nanotube, and diamond and a metal sheet are bonded via the adhesive layer.
- the sheet include a laminate in which a graphite sheet and a metal sheet are bonded via the adhesive layer, a laminate in which an adhesive layer in which carbon fibers are dispersed on the metal sheet, and at least two metal sheets. May be a laminate in which carbon fibers are dispersed through an adhesive layer, and a laminate in which a graphite sheet and a metal sheet are adhered through an adhesive layer in which carbon fibers are dispersed.
- these sheets may be the same sheet, or may be sheets having different thicknesses, shapes, materials, and the like. Good. The same applies to the carbon material.
- the sheet of the present invention is preferably a sheet containing a graphite sheet, in particular, a metal sheet, an adhesive layer, A sheet in which a graphite sheet, an adhesive layer and a metal sheet are laminated in this order is preferable.
- a sheet is lightweight and excellent in heat dissipation characteristics, and thus is suitably used as a heat radiating member, and particularly preferably used as a heat radiating member of a heating element having a high temperature.
- a sheet in which a metal sheet, an adhesive layer, a graphite sheet, an adhesive layer, and a metal sheet are laminated in this order is preferable because the adhesive strength between the metal sheet and the graphite sheet is high and the workability and bendability are excellent.
- the thickness of the sheet of the present invention is not particularly limited, and the thickness of the adhesive layer is about the same as the thickness specified in the column of the adhesive layer.
- the thickness is specified in the column of the graphite sheet.
- the thickness of the metal sheet may be approximately the same as the thickness specified in the column of the metal sheet below, and the total thickness of these layers used depends on the configuration of the laminate. It becomes thickness.
- the thickness of the sheet of the present invention is preferably 10 to 300 ⁇ m, more preferably 15 to 150 ⁇ m.
- the metal sheet is preferably a sheet containing a metal having excellent thermal conductivity, more preferably a sheet containing gold, silver, copper, aluminum, nickel, and an alloy containing at least one of these metals. And more preferably, a sheet containing silver, copper, aluminum, nickel and an alloy containing at least one of these metals, particularly preferably containing copper, aluminum and at least one of these metals. And a sheet containing one kind of metal selected from the group consisting of alloys.
- the alloy may be in any state of a solid solution, a eutectic or an intermetallic compound. Specific examples of the alloy include phosphor bronze, copper nickel, and duralumin.
- the thickness of the metal sheet is not particularly limited, and may be appropriately selected in consideration of the use, weight, thermal conductivity, etc. of the sheet of the present invention to be obtained, but is preferably 5 from the viewpoint of availability. It is ⁇ 1000 ⁇ m, more preferably 10 to 50 ⁇ m, and particularly preferably 12 to 40 ⁇ m. Further, from the viewpoint of obtaining the sheet (heat radiating member) of the present invention having excellent heat dissipation characteristics, the thickness is preferably 0.01 to 100 times that of the graphite sheet, more preferably 0.1 to 10 times. It is thickness.
- the heat radiating member of the present invention includes at least one selected from the composite material and the sheet of the present invention.
- the shape of such a heat radiating member is not particularly limited and may be appropriately selected according to a desired application.
- the sheet of the present invention is formed in a bellows shape. It may be a bent shape.
- the heat radiating member of the present invention is preferably a sheet in which a metal sheet, an adhesive layer, a graphite sheet, an adhesive layer and a metal sheet are laminated in this order.
- a sheet is lightweight and excellent in heat dissipation characteristics, and thus is suitably used as a heat radiating member, and particularly preferably used as a heat radiating member of a heating element having a high temperature.
- the electronic device, battery, capacitor, automotive component, and mechanical mechanism component of the present invention include at least one selected from the composite material, sheet, and heat dissipation member of the present invention.
- the composite material, sheet, or heat dissipation member of the present invention is used in an electronic device, a battery, a capacitor, an automotive part, or a mechanical mechanism part so as to be in contact with a heating element.
- the term “in contact with the heating element” includes not only the case where the composite material, the sheet or the heat radiating member of the present invention directly contacts the heating element but also the case where it contacts the heating element through a conventionally known layer such as an adhesive layer. It is.
- Examples of the electronic device include a chip such as an ASIC (Application Specific Integrated Circuit) used for image processing, television, audio, and the like, a CPU (Central Processing Unit) such as a personal computer and a smartphone, an IGBT, and LED lighting. .
- ASIC Application Specific Integrated Circuit
- CPU Central Processing Unit
- IGBT IGBT
- LED lighting LED lighting.
- Examples of the battery include a lithium ion secondary battery, a nickel metal hydride battery, and a multivalent ion secondary battery used for automobiles and mobile phones (eg, smart phones).
- Capacitor> examples of the capacitor include polyacene capacitors and lithium ion capacitors used for automobiles and mobile phones (eg, smart phones).
- the lithium ion capacitor may be a module in which a plurality of lithium ion capacitor cells are connected in series or in parallel.
- the composite material, sheet or heat dissipation member of the present invention may be disposed so as to be in contact with a part of the outer surface of the entire module or to cover the entire module, and the outer surface of each lithium ion capacitor cell. You may arrange
- Examples of automotive parts and mechanical mechanism parts include ECUs (Electronic Control Units), car navigation systems, power controllers, and soaking heaters.
- ECUs Electronic Control Units
- car navigation systems car navigation systems
- power controllers power controllers
- soaking heaters soaking heaters
- PV-C Vinylec C
- PVF-K Vinylec K
- polyvinyl formal resin weight average molecular weight 45000, not including the structural unit D
- JNC Corporation "Denka Butyral” manufactured by Denki Kagaku Kogyo Co., Ltd., polyvinyl butyral resin (excluding the structural unit D)
- Graphite sheet> Graphite sheet (artificial graphite): manufactured by GrafTECH International, SS-1500 (trade name), thickness 25 ⁇ m, sheet surface direction thermal conductivity 1500 W / m ⁇ K ⁇ Metal plate> ⁇ Copper plate: Nilaco Co., Ltd., thickness 0.02mm
- Example 1 PVF-C (2 g), RPS-1005 (0.1 g), and NMP 20 g were stirred overnight at room temperature to completely dissolve PVF-C and RPS-1005 in NMP. )
- This adhesive is applied to a copper plate having a size of 50 ⁇ 50 mm and a thickness of 0.02 mm using a spin coater (Mikasa Co., Ltd., 1H-D3 type) so that the thickness of the obtained adhesive layer is about 5 ⁇ m. After coating at 1500 rpm, it was pre-dried for 10 minutes on a hot plate set at 80 ° C. to obtain a copper plate with an adhesive coating. In this test, the thickness of the adhesive layer is 5 ⁇ m in order to eliminate the influence of the unevenness of the copper plate and the graphite sheet and accurately evaluate the adhesive layer.
- a small heating press (manufactured by Toyo Seiki Seisakusyo Co., Ltd.) is sandwiched between two copper sheets with adhesive coating, with a 25 ⁇ m-thick graphite sheet (SS-1500) previously cut to 60 ⁇ 60 mm with the adhesive coating side facing inward. : Mini test press-10 type small heating manual press). The depressurization and depressurization were repeated several times while taking care that the position of each of the two copper plates and the graphite sheet was fixed at a predetermined position, and then the pressure was increased to 10 MPa after degassing the adhesive coating film. . Thereafter, the heater was heated to 170 ° C.
- the heater heating temperature when forming the adhesive layer
- the temperature and pressure were maintained for 10 minutes (heating time when forming the adhesive layer).
- the heater was turned off and cooled to about 25 ° C.
- the pressurization was stopped to obtain a composite sheet.
- the thickness of the composite sheet was measured, and 1/2 of the value obtained by subtracting the thickness of the graphite sheet and the two copper plates from the measured value was taken as the thickness of the adhesive layer.
- the thickness of the composite sheet was measured by Digimatic Indicator ID-C112CXB manufactured by Mitutoyo Corporation.
- the adhesive strength between the metal layer (copper plate) and the graphite layer (graphite sheet) of the resulting composite sheet has the characteristic that the graphite layer cleaves (peels within the layer), so values such as tensile load when peeling off It is difficult to ask for. Therefore, the high-temperature adhesiveness of the adhesive layer is determined by placing the obtained composite sheet on a hot plate heated to 120 ° C., peeling off the metal portion of the composite sheet at a temperature of 120 ° C. The state of the inner surface of the layer was evaluated by visual observation.
- the obtained composite sheet was placed on a hot plate heated to 110 ° C, 120 ° C, 130 ° C, 140 ° C, 150 ° C, 160 ° C, 170 ° C, 180 ° C, 190 ° C, 200 ° C or 210 ° C for 10 seconds.
- the shape of the composite sheet was visually confirmed. This test was performed at 110 ° C. at each temperature until the composite sheet swelled using the same composite sheet.
- the shape of the composite sheet is the shape as it was created, and Table 1 shows the temperature immediately before the bulge appears. In this test, for the sake of convenience, the heating time was set to 10 seconds.
- Example 2 to 19 A composite sheet was prepared in the same manner as in Example 1 except that the type of resin, the type or addition amount of the oxazoline compound, or the heating temperature or heating time when forming the adhesive layer was changed as shown in Table 1. Using this composite sheet, high-temperature adhesiveness and heat resistance were evaluated in the same manner as in Example 1.
- Example 20 A PVF solution in which PVF-C (2 g) was dissolved in 20 g of NMP and an RPS solution in which RPS-1005 (0.4 g) was dissolved in 5 g of NMP were prepared.
- an RPS solution was applied to a copper plate having a size of 50 ⁇ 50 mm and a thickness of 0.02 mm using a spin coater (1H-D3 type) at 1500 rpm.
- the PVF solution was applied onto the coated surface under a condition of 1500 rpm with a spin coater (1H-D3 type) in a state where the coated surface of the RPS solution was not dried.
- the obtained copper plate was pre-dried for 10 minutes on a hot plate set at 80 ° C.
- a composite sheet was prepared in the same manner as in Example 12 except that the obtained copper plate with an adhesive coating was used (adhesive layer thickness: about 5 ⁇ m), and in the same manner as in Example 1 using the composite sheet, High temperature adhesion and heat resistance were evaluated.
- Example 1 A composite sheet was prepared in the same manner as in Example 3 except that no oxazoline compound was used, and the high-temperature adhesiveness and heat resistance were evaluated in the same manner as in Example 1 using the composite sheet.
- Example 21 (Create composite sheet) Spin coater (1H-D3 type) with the adhesive obtained in Example 5 on a graphite sheet (SS-1500) having a size of 60 ⁇ 60 mm and a thickness of 25 ⁇ m so that the thickness of the resulting adhesive layer is about 5 ⁇ m.
- SS-1500 graphite sheet
- Example 21 Spin coater (1H-D3 type) with the adhesive obtained in Example 5 on a graphite sheet (SS-1500) having a size of 60 ⁇ 60 mm and a thickness of 25 ⁇ m so that the thickness of the resulting adhesive layer is about 5 ⁇ m.
- SS-1500 graphite sheet having a size of 60 ⁇ 60 mm and a thickness of 25 ⁇ m so that the thickness of the resulting adhesive layer is about 5 ⁇ m.
- Example 1 heat resistance when forming the adhesive layer
- Example 2 heating temperature when forming the adhesive layer
- the temperature and pressure were maintained for 2 minutes (heating time when forming the adhesive layer).
- the heater was turned off and cooled to about 25 ° C.
- the pressurization was stopped to obtain a composite sheet.
- the thickness of the composite sheet was measured, and 1/2 of the value obtained by subtracting the thickness of three graphite sheets from the measured value was defined as the thickness of the adhesive layer.
- the thickness of the composite sheet was measured by Digimatic Indicator ID-C112CXB manufactured by Mitutoyo Corporation. Using the obtained composite sheet, the heat resistance was evaluated in the same manner as in Example 1.
- the adhesive strength between the graphite layers (graphite sheets) of the obtained composite sheet has a characteristic that the graphite layer is cleaved (peeled in the layer), and therefore it is difficult to obtain the value by a numerical value such as a tensile load at the time of peeling. Therefore, the high-temperature adhesiveness of the adhesive layer is determined by placing the obtained composite sheet on a hot plate heated to 120 ° C., peeling off the graphite portion of the composite sheet at a temperature of 120 ° C., and removing the graphite after peeling off. The state of the inner surface of the layer was evaluated by visual observation.
- Example 22 and 23 In Example 21, except that the type of resin, or the type or addition amount of the oxazoline compound was changed as shown in Table 2, a composite sheet was prepared in the same manner as in Example 21, and the composite sheet was used. In the same manner as in Example 21, the high-temperature adhesiveness and heat resistance were evaluated.
- the adhesive layer obtained using the polyvinyl acetal resin and the compound having an oxazoline group is an adherend such as a metal layer or a graphite layer, in particular, a high temperature between the metal layer and the graphite layer and between the graphite layers. It turns out that it is excellent in adhesiveness.
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Abstract
Description
このような熱伝導体として、グラファイトシートと金属板とを、ポリビニルアセタール樹脂を含む組成物から形成される接着層で接着した積層体を用いることが開示されている(特許文献1)。
本発明の構成例は以下のとおりである。
[2] ポリビニルアセタール樹脂が、構成単位A、BおよびCを含む、[1]に記載の組成物。
(構成単位A中、Rは独立に水素またはアルキルである。)
[3] ポリビニルアセタール樹脂が、さらに、構成単位Dを含む、[2]に記載の組成物。
(構成単位D中、R1は独立に水素または炭素数1~5のアルキルである。)
[4] 構成単位AにおけるRが水素または炭素数1~3のアルキルである、[2]または[3]に記載の組成物。
[5] ポリビニルアセタール樹脂1質量部に対し、オキサゾリン基を有する化合物を0.02~1質量部含む、[1]~[4]のいずれかに記載の組成物。
[6] ポリビニルアセタール樹脂と、オキサゾリン基を有する化合物とを用いて得られる接着層。
[7] [1]~[5]のいずれかに記載の組成物を用いて得られる接着層。
[8] 下記工程(1)および(2)を含む、[6]または[7]に記載の接着層の製造方法。
工程(1):ポリビニルアセタール樹脂と、オキサゾリン基を有する化合物とを含む層を形成する工程
工程(2):工程(1)で得られた層を加熱する工程
[9] グラファイトシート、カーボンファイバー、カーボンナノチューブおよびダイヤモンドからなる群より選ばれる1種の炭素材料同士、または、該群より選ばれる少なくとも2種の炭素材料を、[6]または[7]に記載の接着層を介して接着させた複合材。
[10] グラファイトシート、カーボンファイバー、カーボンナノチューブおよびダイヤモンドからなる群より選ばれる少なくとも1種の炭素材料と金属シートとを、[6]または[7]に記載の接着層を介して接着させたシート。
[11] [9]に記載の複合材および[10]に記載のシートから選ばれる少なくとも1つを含む放熱部材。
[12] [9]に記載の複合材、[10]に記載のシートおよび[11]に記載の放熱部材から選ばれる少なくとも1つを含む電子デバイス。
[13] [9]に記載の複合材、[10]に記載のシートおよび[11]に記載の放熱部材から選ばれる少なくとも1つを含むバッテリー。
[14] [9]に記載の複合材、[10]に記載のシートおよび[11]に記載の放熱部材から選ばれる少なくとも1つを含むキャパシタ。
[15] [9]に記載の複合材、[10]に記載のシートおよび[11]に記載の放熱部材から選ばれる少なくとも1つを含む自動車用部品。
[16] [9]に記載の複合材、[10]に記載のシートおよび[11]に記載の放熱部材から選ばれる少なくとも1つを含む機械機構部品。
また、本発明によれば、接着層の厚みが薄くても、被着体、特に金属シートなどの金属材料やグラファイトシートなどの炭素材料との接着性に優れる接着層を形成することができるため、耐熱性、耐久性および放熱特性に優れ、軽量化、小型化可能な、放熱部材、さらには、電子デバイス、バッテリー、キャパシタ、自動車用部品および機械機構部品を提供することができる。
本発明の接着層形成用の組成物(以下単に「本発明の組成物」ともいう。)は、ポリビニルアセタール樹脂とオキサゾリン基を有する化合物とを含む。
本発明の組成物は、前記のような効果を有するため、接着剤ということもできる。
一成分型とするか、二成分型とするかは、所望の要求等に応じて適宜選択すればよく、例えば、容易に接着層を形成するために一成分型としてもよく、保存安定性等を考慮して二成分型にしてもよい。
ポリビニルアセタール樹脂としては、特に制限されないが、靱性、耐熱性および耐衝撃性に優れ、被着体、特に金属シートなどの金属材料やグラファイトシートなどの炭素材料との接着性に優れる接着層が得られる等の点から、下記構成単位A、BおよびCを含む樹脂であることが好ましい。
1mol/l水酸化ナトリウム水溶液中で、ポリビニルアセタール樹脂を、2時間、80℃で加温する。この操作により、カルボキシル基にナトリウムが付加し、-COONaを有するポリマーが得られる。該ポリマーから過剰な水酸化ナトリウムを抽出した後、脱水乾燥を行う。その後、炭化させて原子吸光分析を行い、ナトリウムの付加量を求めて定量する。
なお、構成単位B(ビニルアセテート鎖)の含有率を分析する際に、構成単位Dは、ビニルアセテート鎖として定量されるため、前記JIS K 6728またはJIS K6729に準じて測定された構成単位Bの含有率より、定量した構成単位Dの含有率を差し引き、構成単位Bの含有率を補正する。
検出器:830-RI (日本分光(株)製)
オ-ブン:西尾工業(株)製 NFL-700M
分離カラム:Shodex KF-805L×2本
ポンプ:PU-980(日本分光(株)製)
温度:30℃
キャリア:テトラヒドロフラン
標準試料:ポリスチレン
オストワルド粘度は、ポリビニルアセタール樹脂5gをジクロロエタン100mlに溶解した溶液を用い、20℃で、Ostwald-Cannon Fenske Viscometerを用いて測定することができる。
前記構成単位A、BおよびCを含む樹脂の合成方法は、特に制限されないが、例えば、特開2009-298833号公報に記載の方法を挙げることができる。また、前記構成単位A、B、CおよびDを含む樹脂の合成方法は、特に制限されないが、例えば、特開2010-202862号公報に記載の方法を挙げることができる。
本発明に用いられるオキサゾリン基を有する化合物(以下「オキサゾリン化合物」ともいう。)は、オキサゾリン基を有すれば特に限定されず、低分子化合物であっても重合体であってもよいが、より被着体との接着性に優れる接着層が得られる等の点から、オキサゾリン基を有する重合体が好ましい。
このようなオキサゾリン化合物をポリビニルアセタール樹脂と共に用いることで、高温下での、被着体、特に、金属シートなどの金属材料やグラファイトシートなどの炭素材料に対する接着性に優れる接着層が得られ、さらには、耐熱性に優れる接着層を得ることができる傾向にある。
しかし、オキサゾリン化合物は、ポリビニルアセタール樹脂と反応しても、水などの該反応による副生成物が生成し難い傾向にあるため、該化合物を用いることで、高温下でも、接着性が低下し難く、耐熱性に優れる接着層を得ることができる。一方で、エポキシ化合物などは、反応により水などの副生成物が生成する傾向にあるため、本発明では、このような化合物を用いないことが好ましい。
用いられるモノマーは、単独でも2種類以上でもよい。
オキサゾリン基を有する重合体の市販品としては、例えば、(株)日本触媒製の、エポクロスKシリーズ、エポクロスWSシリーズ、エポクロスRPSが挙げられ、具体的には、エポクロスWS-500、エポクロスRPS-1005が挙げられる。また、オキサゾリン基を有する低分子化合物の市販品としては、例えば、三國製薬工業(株)製の2,2'-(1,3-フェニレン)ビス(2-オキサゾリン)が挙げられる。
オキサゾリン化合物は、単独で用いてもよく、2種以上を用いてもよい。
本発明の組成物は、溶剤を含んでもよく、含まなくてもよいが、接着層の形成容易性等の点から、溶剤を含むことが好ましい。該溶剤としては、前記ポリビニルアセタール樹脂および前記オキサゾリン化合物を溶解できるものであることが好ましい。このような溶剤としては、メタノール、エタノール、n-プロパノール、iso-プロパノール、1-メトキシ-2-プロパノール、n-ブタノール、sec-ブタノール、n-オクタノール、ジアセトンアルコール、ベンジルアルコールなどのアルコール系溶媒;メチルセロソルブ、エチルセロソルブ、ブチルセロソルブなどのセロソルブ系溶媒;アセトン、メチルエチルケトン、シクロペンタノン、シクロヘキサノン、イソホロンなどのケトン系溶媒;N,N-ジメチルアセトアミド、N,N-ジメチルホルムアミド、1-メチル-2-ピロリドンなどのアミド系溶媒;酢酸メチル、酢酸エチルなどのエステル系溶媒;ジオキサン、テトラヒドロフランなどのエーテル系溶媒;メチレンクロライド、クロロホルムなどの塩素化炭化水素系溶媒;トルエン、ピリジンなどの芳香族系溶媒;ジメチルスルホキシド;酢酸;テルピネオール;ブチルカルビトール;ブチルカルビトールアセテート等の有機溶剤や水が挙げられる。
これらの溶剤は、単独で用いてもよく、2種以上を用いてもよい。
本発明の組成物には、通常用いられる範囲で安定剤、改質剤等の添加剤を加えてもよい。このような添加剤としては、市販されている添加剤を使用できる。また、本発明の組成物には、ポリビニルアセタール樹脂の特性を損なわない範囲で他の樹脂を添加することもできる。
これらの添加剤は、それぞれ、単独で用いてもよく、2種以上を用いてもよい。
シランカップリング剤の添加量は、金属シートとの接着性を向上させることができるなどの点から、本発明の組成物に含まれる樹脂の総量100質量部に対して、好ましくは1~10質量部である。
銅害防止剤の添加量は、接着層の金属と接触する部分の樹脂の劣化を防止できるなどの点から、本発明の組成物に含まれる樹脂の総量100質量部に対して、好ましくは0.1~3質量部である。
本発明の組成物は、熱伝導率を向上させることを目的として少量の熱伝導性フィラーを含んでいてもよいが、熱伝導性フィラーの多量の添加は接着性能を低下させる可能性があるので添加する際には添加量と接着性能とのバランスに留意する必要がある。
これらの熱伝導性フィラーは、単独で用いてもよく、2種以上を用いてもよい。
本発明の組成物は、ポリビニルアセタール樹脂と、オキサゾリン化合物と、必要により前記溶剤や添加剤とを混合することにより得ることができる。
本発明の組成物が一成分型の組成物である場合、該組成物としては、ポリビニルアセタール樹脂とオキサゾリン化合物とを溶剤に溶解させることで調製された一液型の組成物であることが好ましく(必要により前記添加剤を含む)、本発明の組成物が二成分型の組成物である場合、該組成物としては、ポリビニルアセタール樹脂を溶剤に溶解させた一液と、オキサゾリン化合物を溶剤に溶解させた一液との二液型の組成物が好ましい(必要により前記添加剤を含む)。二液型の組成物の場合、必要により配合される前記添加剤は、どちらか一方の液に配合してもよく、両方の液に配合してもよい。
本発明の接着層は、ポリビニルアセタール樹脂とオキサゾリン化合物とを用いて得られる層、または前記本発明の組成物を用いて得られる層である。
このような接着層は、高温下、具体的には約120℃以上の温度下でも、また、厚みが薄くても、被着体、特に金属シートなどの金属材料やグラファイトシートなどの炭素材料との接着性に優れるため、このような接着層を用いることで、耐熱性、耐久性および放熱特性に優れ、軽量化、小型化可能な、放熱部材、さらには、電子デバイス、バッテリー、キャパシタ、自動車用部品および機械機構部品を得ることができる。
本発明の接着層は、ポリビニルアセタール樹脂とオキサゾリン化合物とを含むため、該接着層の厚みが1μm以下の厚みであっても被着体、特に金属シートなどの金属材料やグラファイトシートなどの炭素材料を接着できる。
本発明の接着層の製造方法としては、特に制限されないが、下記工程(1)および(2)を含む製造方法が好ましい。
工程(1):ポリビニルアセタール樹脂とオキサゾリン化合物とを含む層を形成する工程
工程(2):工程(1)で得られた層を加熱する工程
工程(1)は、ポリビニルアセタール樹脂とオキサゾリン化合物とを含む層を形成する工程である。
この工程(1)では、前記本発明の組成物、特に、前記一液型の組成物または二液型の組成物を用いることが好ましい。
なお、二液型の組成物を用いる場合には、2つの液を予め混合してから被着体上に塗布してもよく、1つの液を被着体上に塗布し、そこに、もう1つの液を塗布してもよい。後者の場合、1つの液を被着体上に塗布し予備乾燥した後、もう1つの液を塗布してもよいが、高温下での接着性および耐熱性に優れる接着層が得られる等の点から、1つの液を被着体上に塗布した後、該液が乾燥しないうちにもう1つの液を塗布することが好ましい。
前記予備乾燥の条件としては、特に制限されず、用いる組成物等に応じて適宜選択すればよいが、例えば、予備乾燥温度は、60~120℃であり、乾燥時間は、1~30分程度である。
工程(2)は、工程(1)で得られた層を加熱する工程である。この工程により接着層が得られる。
工程(2)における加熱温度は、被着体の耐熱温度等にもよるが、高温下での接着性に優れる接着層が得られる等の点から、好ましくは150~250℃であり、より好ましくは170~220℃であり、さらに耐熱性により優れる接着層が得られる等の点から特に好ましくは200~220℃である。
本発明の複合材は、グラファイトシート、カーボンファイバー、カーボンナノチューブおよびダイヤモンドからなる群より選ばれる1種の炭素材料同士、または、該群より選ばれる少なくとも2種の炭素材料を、前記接着層を介して接着させた複合材である。
グラファイトシートは、グラファイトからなるシートであれば、特に制限されないが、例えば、特開昭61-275117号公報および特開平11-21117号公報に記載の方法で製造したものを用いてもよいし、市販品を用いてもよい。
この熱伝導率は、レーザーフラッシュまたはキセノンフラッシュ熱拡散率測定装置、DSCおよびアルキメデス法で、それぞれ熱拡散率、比熱および密度を測定し、これらを掛け合わせることで算出することができる。
なお、グラファイトシートとしては、その一部に穴やスリットが設けられたシートであってもよい。
本発明のシートは、グラファイトシート、カーボンファイバー、カーボンナノチューブおよびダイヤモンドからなる群より選ばれる少なくとも1種の炭素材料と金属シートとを、前記接着層を介して接着させたシートである。
このシートとしては、例えば、グラファイトシートと金属シートとが前記接着層を介して接着した積層体、金属シート上にカーボンファイバー等が分散した接着層が積層された積層体、少なくとも2枚の金属シートがカーボンファイバー等が分散した接着層を介して接着された積層体、グラファイトシートと金属シートとがカーボンファイバー等が分散した接着層を介して接着された積層体が挙げられる。なお、この場合、得られるシート中に、少なくとも2枚の金属シートが含まれる場合には、これらのシートは同一のシートであってもよく、厚みや形状、材質等の異なるシートであってもよい。炭素材料も同様である。
本発明のシートの厚みは、具体的には、好ましくは10~300μmであり、より好ましくは15~150μmである。
金属シートを用いることで、本発明のシートの熱容量、機械的強度および加工性などが向上する。
前記金属シートとしては、熱伝導性に優れる金属を含むシートであることが好ましく、より好ましくは金、銀、銅、アルミニウム、ニッケルおよびこれらの少なくともいずれか1つの金属を含有する合金を含むシートが挙げられ、さらに好ましくは銀、銅、アルミニウム、ニッケルおよびこれらの少なくともいずれか1つの金属を含有する合金を含むシートが挙げられ、特に好ましくは銅、アルミニウムおよびこれらの少なくともいずれか1つの金属を含有する合金からなる群より選ばれる1種の金属を含むシートが挙げられる。
前記合金は、固溶体、共晶または金属間化合物のいずれの状態であってもよい。
前記合金としては、具体的には、リン青銅、銅ニッケル、ジュラルミンなどが挙げられる。
本発明の放熱部材は、前記本発明の複合材およびシートから選ばれる少なくとも1つを含む。
このような放熱部材の形状は特に制限されず、所望の用途に応じて適宜選択すればよいが、例えば、放熱特性に優れる放熱部材を得ることを目的として、前記本発明のシートを蛇腹状に折り曲げた形状であってもよい。
本発明の電子デバイス、バッテリー、キャパシタ、自動車用部品および機械機構部品は、前記本発明の複合材、シートおよび放熱部材から選ばれる少なくとも1つを含む。
具体的には、本発明の複合材、シートまたは放熱部材は、電子デバイス、バッテリー、キャパシタ、自動車用部品または機械機構部品において、これらのうちの、発熱体に接するように配置されて使用される。
なお、「発熱体に接する」とは、本発明の複合材、シートまたは放熱部材が直接発熱体に接する場合の他、接着剤層などの従来公知の層を介して発熱体に接する場合も含まれる。
電子デバイスとしては、例えば、画像処理やテレビ、オーディオなどに使用されるASIC(Application Specific Integrated Circuit)等のチップ、パーソナルコンピュータ、スマートフォンなどのCPU(Central Processing Unit)、IGBT、LED照明などが挙げられる。
バッテリーとしては、自動車や携帯電話(例:スマートフォン)などに用いられるリチウムイオン二次電池、ニッケル水素電池、多価イオン二次電池などが挙げられる。
キャパシタとしては、自動車や携帯電話(例:スマートフォン)などに用いられるポリアセンキャパシタ、リチウムイオンキャパシタなどが挙げられる。
この場合、本発明の複合材、シートまたは放熱部材は、モジュール全体の外表面の一部に接するように、またはモジュール全体を覆うように配置してもよく、各リチウムイオンキャパシタセルの外表面の一部に接するように、または各セルを覆うように配置してもよい。
自動車用部品や機械機構部品としては、例えば、ECU(Electronic Control Unit)、カーナビゲーション、パワーコントローラー、均熱ヒーターが挙げられる。
本発明の実施例に用いた材料は次のとおりである。
・「PVF-C」:ビニレック C(商品名):JNC(株)製、ポリビニルホルマール樹脂(重量平均分子量64000、前記構成単位D含有)
・「PVF-K」:ビニレック K(商品名):JNC(株)製、ポリビニルホルマール樹脂(重量平均分子量45000、前記構成単位D不含)
・「デンカブチラール」:電気化学工業(株)製、ポリビニルブチラール樹脂(前記構成単位D不含)
・「RPS-1005」:エポクロス RPS-1005(商品名):(株)日本触媒製、オキサゾリン基含有ポリマー
・「WS-500」:エポクロス WS-500(商品名):(株)日本触媒製、オキサゾリン基含有ポリマー(不揮発分39%)
・「1,3-BPO」:2,2'-(1,3-フェニレン)ビス(2-オキサゾリン):三國製薬工業(株)製
・「NMP」:1-メチル-2-ピロリドン:和光純薬工業(株)製、和光特級
・グラファイトシート(人工グラファイト):GrafTECH International製、SS-1500(商品名)、厚み25μm、シートの面方向の熱伝導率1500W/m・K
<金属板>
・銅板:(株)ニラコ製、厚み0.02mm
PVF-C(2g)と、RPS-1005(0.1g)と、NMP20gとを室温で一晩攪拌し、PVF-CおよびRPS-1005をNMPに完全に溶解させることで、接着剤(組成物)を得た。
この接着剤を、大きさ50×50mm、厚み0.02mmの銅板に、得られる接着層の厚みが約5μmになるようにスピンコーター(ミカサ(株)製、1H-D3型)を用いて、1500回転/分の条件で塗布した後、80℃に設定したホットプレート上で10分間予備乾燥し、接着塗膜付き銅板を得た。
なお、この試験では、銅板やグラファイトシートの凹凸の影響をなくし、接着層の評価を正確に行うために接着層を5μmの厚みにしている。
なお、この複合シートの厚みを測定し、この測定値からグラファイトシートおよび2枚の銅板の厚みを差し引いた値の1/2を接着層の厚みとした。複合シートの厚みは(株)ミツトヨ製デジマチックインジケータID-C112CXBにより測定した。
得られた複合シートの金属層(銅板)とグラファイト層(グラファイトシート)との接着強度は、グラファイト層が、劈開(層内で剥離)する特性があるので、引き剥がす際の引っ張り荷重などの数値で求めることは難しい。
従って、接着層の高温接着性は、得られた複合シートを120℃に加熱したホットプレート上に置き、120℃の温度下で、該複合シートの金属部分を引き剥がし、引き剥がした後の金属層内側表面の状態を目視で観察することにより評価した。引き剥がした金属層の表面全体が、劈開したグラファイトで覆われている場合を○、金属層または接着層が現れている場合を×とした。目視観察において、○と判別したものの、引き剥がした後の引き剥がし面の赤外線吸収スペクトルをサーモフィッシャー製iS10型のATRアダプタを用いて測定し、該スペクトルから、引き剥がし面にポリビニルアセタール樹脂が存在しているか否かを観察することにより評価した。引き剥がし面にポリビニルアセタール樹脂が存在していない場合を◎とし、引き剥がし面にポリビニルアセタール樹脂が存在していた場合を×とした。つまり、目視観察および赤外線吸収スペクトル評価の両方において、引き剥がした金属層の表面全体に金属層または接着層(ポリビニルアセタール樹脂)が観察できなかったものを表1では◎と表記し、目視観察または赤外線吸収スペクトル評価のいずれかにおいて、×となった場合を表1では×と表記する。
得られた複合シートを、110℃、120℃、130℃、140℃、150℃、160℃、170℃、180℃、190℃、200℃または210℃に加温したホットプレート上に10秒間置き、複合シートの形状を目視により確認した。この試験は、同一の複合シートを用いて、複合シートに膨らみが生じるまで、110℃から順に各温度で行った。複合シートの形状が作成時のままの形状であり、膨らみが出る直前の温度を表1に示す。
なお、この試験では、便宜上、加熱時間を10秒間としたが、所定の試験において、10秒間加熱して複合シートの形状が変化しない場合には、2時間以上加熱しても複合シートの形状は変化しないことを確認している。従って、10秒間の加熱に耐えうる複合シートは、該加熱温度での耐性を有するといえる。
樹脂の種類、オキサゾリン化合物の種類もしくは添加量、または、接着層形成時の加熱温度もしくは加熱時間を表1に示すように変更したこと以外は、実施例1と同様にして複合シートを作成し、該複合シートを用いて実施例1と同様にして、高温接着性および耐熱性を評価した。
PVF-C(2g)をNMP20gに溶解させたPVF溶液と、RPS-1005(0.4g)をNMP5gに溶解させたRPS溶液とを調製した。
まず、大きさ50×50mm、厚み0.02mmの銅板に、RPS溶液をスピンコーター(1H-D3型)を用いて、1500回転/分の条件で塗布した。その後、RPS溶液の塗布面が乾燥していない状態で、該塗布面上にPVF溶液をスピンコーター(1H-D3型)を用いて、1500回転/分の条件で塗布した。次いで、得られた銅板を80℃に設定したホットプレート上で10分間予備乾燥し、接着塗膜付き銅板を得た。
得られた接着塗膜付き銅板を用いた以外は実施例12と同様にして、複合シートを作成し(接着層の厚み:約5μm)、該複合シートを用いて実施例1と同様にして、高温接着性および耐熱性を評価した。
オキサゾリン化合物を用いないこと以外は、実施例3と同様にして複合シートを作成し、該複合シートを用いて実施例1と同様にして、高温接着性および耐熱性を評価した。
(複合シートの作成)
実施例5で得られた接着剤を、大きさ60×60mm、厚み25μmのグラファイトシート(SS-1500)に、得られる接着層の厚みが約5μmになるようにスピンコーター(1H-D3型)を用いて、3000回転/分の条件で塗布した後、80℃に設定したホットプレート上で10分間予備乾燥し、接着塗膜付きグラファイトシートを得た。
なお、この複合シートの厚みを測定し、この測定値からグラファイトシート3枚の厚みを差し引いた値の1/2を接着層の厚みとした。複合シートの厚みは(株)ミツトヨ製デジマチックインジケータID-C112CXBにより測定した。
得られた複合シートを用い、実施例1と同様にして耐熱性の評価を行った。
得られた複合シートのグラファイト層(グラファイトシート)間の接着強度は、グラファイト層が、劈開(層内で剥離)する特性があるので、引き剥がす際の引っ張り荷重などの数値で求めることは難しい。
従って、接着層の高温接着性は、得られた複合シートを120℃に加熱したホットプレート上に置き、120℃の温度下で、該複合シートのグラファイト部分を引き剥がし、引き剥がした後のグラファイト層内側表面の状態を目視で観察することにより評価した。引き剥がしたグラファイト層の表面全体が、劈開したグラファイトのみで覆われている場合を○、接着層が現れている場合を×とした。目視観察において、○と判別したものの、引き剥がした後の引き剥がし面の赤外線吸収スペクトルをサーモフィッシャー製iS10型のATRアダプタを用いて測定し、該スペクトルから、引き剥がし面にポリビニルアセタール樹脂が存在しているか否かを観察することにより評価した。引き剥がし面にポリビニルアセタール樹脂が存在していない場合を◎とし、引き剥がし面にポリビニルアセタール樹脂が存在していた場合を×とした。つまり、目視観察および赤外線吸収スペクトル評価の両方において、引き剥がしたグラファイト層の表面全体に接着層(ポリビニルアセタール樹脂)が観察できなかったものを表2では◎と表記し、目視観察または赤外線吸収スペクトル評価のいずれかにおいて、×となった場合を表2では×と表記する。
実施例21において、樹脂の種類、または、オキサゾリン化合物の種類もしくは添加量を表2に示すように変更したこと以外は、実施例21と同様にして、複合シートを作成し、該複合シートを用いて実施例21と同様にして、高温接着性および耐熱性を評価した。
それぞれ、実施例21および実施例23において、オキサゾリン化合物を用いないこと以外は、実施例21と同様にして、複合シートを作成し、該複合シートを用いて実施例21と同様にして、高温接着性および耐熱性を評価した。
Claims (16)
- ポリビニルアセタール樹脂と、オキサゾリン基を有する化合物とを含む、接着層形成用の組成物。
- 構成単位AにおけるRが水素または炭素数1~3のアルキルである、請求項2または3に記載の組成物。
- ポリビニルアセタール樹脂1質量部に対し、オキサゾリン基を有する化合物を0.02~1質量部含む、請求項1~4のいずれか1項に記載の組成物。
- ポリビニルアセタール樹脂と、オキサゾリン基を有する化合物とを用いて得られる接着層。
- 請求項1~5のいずれか1項に記載の組成物を用いて得られる接着層。
- 下記工程(1)および(2)を含む、請求項6または7に記載の接着層の製造方法。
工程(1):ポリビニルアセタール樹脂と、オキサゾリン基を有する化合物とを含む層を形成する工程
工程(2):工程(1)で得られた層を加熱する工程 - グラファイトシート、カーボンファイバー、カーボンナノチューブおよびダイヤモンドからなる群より選ばれる1種の炭素材料同士、または、該群より選ばれる少なくとも2種の炭素材料を、請求項6または7に記載の接着層を介して接着させた複合材。
- グラファイトシート、カーボンファイバー、カーボンナノチューブおよびダイヤモンドからなる群より選ばれる少なくとも1種の炭素材料と金属シートとを、請求項6または7に記載の接着層を介して接着させたシート。
- 請求項9に記載の複合材および請求項10に記載のシートから選ばれる少なくとも1つを含む放熱部材。
- 請求項9に記載の複合材、請求項10に記載のシートおよび請求項11に記載の放熱部材から選ばれる少なくとも1つを含む電子デバイス。
- 請求項9に記載の複合材、請求項10に記載のシートおよび請求項11に記載の放熱部材から選ばれる少なくとも1つを含むバッテリー。
- 請求項9に記載の複合材、請求項10に記載のシートおよび請求項11に記載の放熱部材から選ばれる少なくとも1つを含むキャパシタ。
- 請求項9に記載の複合材、請求項10に記載のシートおよび請求項11に記載の放熱部材から選ばれる少なくとも1つを含む自動車用部品。
- 請求項9に記載の複合材、請求項10に記載のシートおよび請求項11に記載の放熱部材から選ばれる少なくとも1つを含む機械機構部品。
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US15/543,238 US10557062B2 (en) | 2015-01-16 | 2016-01-13 | Composition for forming adhesive layer, adhesive layer, manufacturing method for adhesive layer, composite material, sheet, heat dissipation member, electronic device, battery, capacitor, automobile component and machine mechanism component |
JP2016569488A JP6206606B2 (ja) | 2015-01-16 | 2016-01-13 | 接着層形成用の組成物、接着層、接着層の製造方法、複合材、シート、放熱部材、電子デバイス、バッテリー、キャパシタ、自動車用部品および機械機構部品 |
EP16737388.5A EP3249023A4 (en) | 2015-01-16 | 2016-01-13 | Composition for forming adhesive layer, adhesive layer, manufacturing method for adhesive layer, composite material, sheet, heat dissipation member, electronic device, battery, capacitor, automobile component, and machine mechanism component |
CN201680005353.8A CN107109160B (zh) | 2015-01-16 | 2016-01-13 | 接着层形成用的组合物、接着层及其制造方法、复合材、片、放热构件及其应用 |
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CN107109160A (zh) | 2017-08-29 |
US10557062B2 (en) | 2020-02-11 |
EP3249023A4 (en) | 2018-08-15 |
KR20170105036A (ko) | 2017-09-18 |
JP6206606B2 (ja) | 2017-10-04 |
TW201627451A (zh) | 2016-08-01 |
TWI675085B (zh) | 2019-10-21 |
JPWO2016114317A1 (ja) | 2017-11-02 |
EP3249023A1 (en) | 2017-11-29 |
CN107109160B (zh) | 2020-05-26 |
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