WO2016201659A1 - Thermally conductive elastomeric composites - Google Patents
Thermally conductive elastomeric composites Download PDFInfo
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- WO2016201659A1 WO2016201659A1 PCT/CN2015/081738 CN2015081738W WO2016201659A1 WO 2016201659 A1 WO2016201659 A1 WO 2016201659A1 CN 2015081738 W CN2015081738 W CN 2015081738W WO 2016201659 A1 WO2016201659 A1 WO 2016201659A1
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- C09K5/00—Heat-transfer, heat-exchange or heat-storage materials, e.g. refrigerants; Materials for the production of heat or cold by chemical reactions other than by combustion
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- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/16—Elastomeric ethene-propene or ethene-propene-diene copolymers, e.g. EPR and EPDM rubbers
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L53/00—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L53/02—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers of vinyl-aromatic monomers and conjugated dienes
- C08L53/025—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers of vinyl-aromatic monomers and conjugated dienes modified
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- C08K7/02—Fibres or whiskers
- C08K7/04—Fibres or whiskers inorganic
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- C08L2203/00—Applications
- C08L2203/20—Applications use in electrical or conductive gadgets
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- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
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- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
- C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
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- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/22—Mixtures comprising a continuous polymer matrix in which are dispersed crosslinked particles of another polymer
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2312/00—Crosslinking
- C08L2312/02—Crosslinking with dienes
Definitions
- Embodiments of this invention relate to a composition composed of a crosslinked interpolymer elastomer and thermally conductive filler dispersed within an elastomeric matrix, thermally conductive articles made from the composition, and methods of producing the composition and articles.
- thermally conductive elastomeric materials are becoming increasingly important to the overall performance of electronic device packages.
- Key components that provide heat dissipation in such devices include, for example, thermal interface materials (e.g., thermal pads, thermal gels, etc. ) and heat conductive rubber seals, among others.
- High temperature resistant materials such as silicone rubber, fluoroelastomers (FPM) , and thermally conductive elastomeric materials are often used for such components to dissipate and effectively manage heat that is generated within electronic devices.
- Thermally conductive fillers which can also be electrically insulating or electrically conductive, are typically added to an elastomeric material to increase thermal conductivity (Tc) .
- Tc thermal conductivity
- a high volume of filler is usually needed to form the network needed to convert an elastomer material from essentially a heat insulator to a thermally conductive material.
- a high volume fraction of inorganic filler is known to have a negative effect on other properties of the elastomer material such as softness, compression set, compound viscosity, etc.
- the invention provides a composition comprising at least the following:
- A)a continuous phase comprising an elastomer selected from the group consisting of an ethylene/ ⁇ -olefin interpolymer, a propylene/ ⁇ -olefin interpolymer, a propylene/ethylene interpolymer, and combinations thereof;
- thermoly conductive filler comprising a plurality of particles dispersed within the continuous phase.
- the invention provides a crosslinked thermally conductive composition formed from the composition as disclosed herein.
- the invention provides an article comprising at least one component formed from the composition as disclosed herein.
- the invention provides a method of providing a crosslinked thermally conductive material comprising thermally conductive filler and domains of crosslinked elastomer dispersed within a continuous phase elastomer matrix.
- a thermally conductive elastomeric composition comprising at least (a) a continuous phase comprising an elastomeric interpolymer (or elastomer) matrix, (b) a discontinuous phase comprising domains of a crosslinked elastomer dispersed or suspended within the continuous phase, and (c) a thermally conductive filler dispersed or suspended within the continuous phase.
- certain embodiments concern crosslinked compositions and articles of manufacture employing such thermally conductive materials, and methods for preparing the thermally conductive materials.
- the elastomer of the matrix component and/or the crosslinked discontinuous phase can be a combination of two or more of the described elastomers.
- an elastomer having one or more properties outside a desired range may be combined with a second elastomer so that the blend of the two elastomers has the desired properties.
- the same elastomer is used for both the matrix component (continuous phase) and for the dispersed crosslinked component (discontinuous phase) .
- different elastomers are used for the matrix component. Use of the same elastomer for both components promotes compatibility and a better interface between the continuous and discontinuous phases.
- one component of the thermally conductive composition described herein is an elastomeric polymer ( "elastomer” ) matrix as the continuous phase.
- the elastomer is an ethylene-based interpolymer, a propylene-based interpolymer, or a combination thereof.
- the uncrosslinked continuous phase elastomer matrix is compounded with the filler component and the crosslinked component.
- the crosslinked component forms the discontinuous phase of the composition, which is dispersed within the elastomer matrix.
- the continuous phase elastomer matrix is cured such that interpolymers of the elastomer matrix are crosslinked.
- the thermally conductive composition comprises the elastomer matrix (continuous phase) in an amount ranging from 20 to 75 volume percent ( "vol%” ) , or from 40 to 60 vol%, based on the total volume of the elastomer matrix, the crosslinked elastomer discontinuous phase, and the thermally conductive filler.
- the elastomer of the elastomeric matrix has a density ranging from 0.8 to 1.4 g/cm 3 , or from 0.85 to 0.95 g/cm 3 .
- the elastomer of the elastomeric matrix has a melt index of ⁇ 0.5 to 30, or of 0.5 to 20, or of 0.5 to 10, g/10 min.
- the elastomer of the elastomeric matrix has a Mooney viscosity (ML1+4, 125°C) of from 5 to 150, or 10 to 100, or 20 to 90, or 30 to 80.
- Illustrative ethylene/ ⁇ -olefin elastomers include ethylene/propylene copolymers, ethylene/1-butene copolymers, ethylene/1-hexene copolymers, ethylene/1-octene copolymers, and ethylene/ ⁇ -olefin/nonconjugated polyene interpolymers, or combinations of two or more thereof.
- the diene is 5-ethylidene-2-norbornene (ENB) .
- the ethylene/ ⁇ -olefin/nonconjugated polyene interpolymer comprises 40 to 80 wt%ethylene, and 0.1 to 15 wt%polyene.
- the ethylene-based interpolymer has a density ranging from 0.8 to 1.4 g/cm 3 , or from 0.85 to 0.93 g/cm 3 .
- the ethylene-based interpolymer has a melt index (I 2 ) ranging from less than 0.5 to 30 g/10 min., or from 0.1, or from 0.2, or from 0.3, or from 0.4, or from 0.5, up to 30, or to 15, or to 10, or to 5, g/10 min.
- I 2 melt index
- the ethylene-based interpolymer has a Mooney viscosity, ML(1+4) at 125°C., from 5, or from 10, or from 15, or from 20, or from 30, and up to 150, or to 100, or to 90, or to 80, for example, from 20 to 80.
- the ethylene-based interpolymer has a molecular weight distribution (Mw/Mn) from 1.5 to 8, or from 2 to 4.
- Propylene-based interpolymers suitable for use herein are propylene/ ⁇ -olefin interpolymers and propylene/ethylene interpolymers.
- the elastomer is a propylene-based interpolymer having polymerized therein propylene and an ⁇ -olefin comonomer.
- the elastomer is an interpolymer of propylene and ethylene.
- the propylene-based interpolymer is an ethylene/propylene/nonconjugated polyene interpolymer with a majority weight of propylene (based on the weight of the interpolymer.
- the ethylene/propylene/nonconjugated polyene interpolymer is an ethylene/propylene/diene terpolymer (EPDM) .
- Illustrative dienes include 5 ethylidene-2-norbornene (ENB) , dicyclopentadiene, 1, 4 hexadiene, 7-methyl-1, 6-octadiene.
- the diene is 5-ethylidene-2-norbornene (ENB) .
- the ethylene/propylene/nonconjugated polyene interpolymer comprises 30 to 45 wt%ethylene, 45 to 70 wt%propylene, and 0.1 to 15 wt%polyene.
- the propylene -based interpolymer has a density ranging from 0.8 to 1 g/cm 3 , or from 0.85 to 0.95 g/cm 3 .
- the propylene-based interpolymer has a melt index (I 2 ) ranging from less than 0.5 to 30 g/10 min., or from 0.1, or from 0.2, or from 0.3, or from 0.4, or from 0.5, up to 30, or to 15, or to 10, or to 5, g/10 min.
- I 2 melt index
- the propylene-based interpolymer has a Mooney viscosity, ML(1+4) at 125°C., from 5, or from 10, or from 15, or from 20, or from 30, and up to 150, or to 100, or to 90, or to 80.
- the elastomer is a random propylene interpolymer.
- Random propylene interpolymers typically comprise 90 or more mole %units derived from propylene, with the remainder of the units derived from units of at least one ⁇ -olefin.
- the ⁇ -olefin component of the random propylene copolymer is preferably ethylene (considered an ⁇ -olefin for purposes of this invention) or a C 4-20 linear, branched or cyclic ⁇ -olefin, as discussed herein.
- Illustrative random polypropylene interpolymers include but are not limited to propylene/ethylene, propylene/1-butene, propylene/1-hexene, propylene/1-octene, and the like.
- Random copolymer polypropylenes are commercially available and include VERSIFY TM propylene-based elastomers, available from The Dow Chemical Company; and VISTAMAXX TM propylene-based elastomers, available from ExxonMobil Chemical, Houston, TX, USA.
- the crosslinked elastomer is a crosslinked ethylene-based interpolymer, a crosslinked propylene-based interpolymer, or combination thereof.
- Ethylene-based interpolymers and propylene-based interpolymers suitable for use as the crosslinked elastomer component are ethylene/ ⁇ -olefin interpolymers and propylene/ ⁇ -olefin interpolymers, and combinations thereof, as described herein.
- the crosslinked elastomer component of the discontinuous phase of the composition is combined with the elastomers of the continuous phase as pre-formed particles.
- the particles can be formed by crosslinking the elastomers (interpolymers) in a conventional manner, for example, using a free radical iniator such as peroxides, phenols, azides, among others.
- the crosslinked material can be formed into particles by mechanical crushing or grinding. The shape of the particles, and thus the dispersed domains of the crosslinked elastomer within the composition, can vary.
- the particles (i.e., the dispersed domains) forming the discontinuous phase of the composition have an average diameter or width that is greater than or equal to 20, or greater than or equal to 30, or greater than or equal to 40, or greater than or equal to 50, and less than or equal to 500 ⁇ m, or less than or equal to 400 ⁇ m, or less than or equal to 300 ⁇ m, or less than or equal to 200 ⁇ m, or less than or equal to 100 ⁇ m. In embodiments, the particles have an average diameter or width of 20 to 500 ⁇ m, or 50 to 200 ⁇ m.
- the elastomer component of the discontinuous phase is crosslinked to a degree to provide a crosslinked material having a gel content of greater than or equal to 20 wt%, or greater than or equal to 30 wt%, or greater than or equal to 40 wt%, or greater than or equal to 50 wt%, or greater than or equal to 60 wt%, or greater than or equal to 70 wt%, or greater than or equal to 80 wt%, or greater than or equal to 90 wt%, up to 100 wt%, insolubles.
- the degree of crosslinking can be measured by dissolving the crosslinked elastomer component in a solvent for a specified duration, and calculating the percent gel or unextractable component.
- thermally conductive filler is dispersed or suspended within the continuous phase elastomeric matrix with the crosslinked elastomeric polymer domains.
- the thermally conductive filler has a thermal conductivity of greater than or equal to 20 Watts per meter per Kelvin (W/m K) , or greater than or equal to 30, or greater than or equal to 50, or greater than or equal to 100, or greater than or equal to 200, up to 1500, or up to 1000, or up to 800, W/m K. In embodiments, the thermally conductive filler has a thermal conductivity ranging from 20 to 1500, or 50 to 1000, or from 100 to 800, W/m K.
- thermally conductive fillers suitable for use herein include, but are not limited to, graphite, aluminum, aluminum oxide (Al 2 O 3 ) , magnesium oxide (MgO) , boron nitride (BN) , zinc oxide (ZnO) , silicon carbide (SiC) , aluminum nitride (AlN) , carbon fiber, silicon nitride, graphene nanoplatelets, zinc sulfide, and combinations thereof.
- the thermally conductive filler is selected from the group consisting of graphite and aluminum. Tc values of such fillers are known in the art. See, for example, Handbook of Fillers (Materials Science) , by George Wypych (Author) , ISBN-13: 978-1884207693.
- the filler particles have an average aspect ratio of from 1: 1 to 1: 100, or from 1: 5 to 1: 80, and preferably from 1: 10 to 1: 50.
- the particles can be shaped as platelets or plates (i.e., platy-shaped) , fibers (i.e., fibrous material) , rods, needles, granules, spheres, or any combination thereof.
- platy-shaped particles have a relatively large particle diameter and relatively small thickness
- rod-, needle- and fibrous-shaped particles have a relatively small diameter and long length.
- the thermally conductive filler is a platy shape.
- the particles are platy-shaped particles with an average width or diameter of 5 to 300 ⁇ m, and an average thickness of 0.5 to 10 ⁇ m.
- the particles are rod-, needle-and fibrous-shaped with an average diameter of 0.5 to 10 ⁇ m and an average length of 15 to 500 ⁇ m.
- the particles are spherical or granular-shaped with an average diameter of 5 to 200 ⁇ m.
- the composition includes an amount of the thermally conductive filler to provide an overall thermal conductivity of at least 0.5, or at least 1.0, or at least 1.5, , and up to 10.0, or up to 8.0, or up to 5.0, W/m K, and, in embodiments, 1.0 to 10.0, or 1.5 to 8, W/m K.
- the thermally conductive filler can be present in the thermally conductive material in an amount of greater than or equal to 20, or greater than or equal to 30, and up to 60, or up to 50, vol%, based on the total volume of the composition.
- the amount of the thermally conductive filler ranges from 20 to 60 vol%, preferably from 30 to 50 vol%, based on the total volume of the composition.
- Thermally conductive fillers are known in the art and commercially available. Examples of commercially available thermally conductive fillers of different particle sizes for use herein include graphite platelets available from Qingdao Tianheda Graphite Co. Ltd (China) , fibrous-shaped particles available from Nippon Graphite Fiber Corporation, and sphere-shaped particles available from Henan Yuanyang Aluminum Industry Co., Ltd (China) .
- the thermally conductive filler can be a single filler or a combination of two or more fillers that differ in at least one property such as particle shape, average particle size, particle size distribution, and type of filler.
- compositions can further include one or more crosslinking agents.
- crosslinking agents include, but are not limited to a sulfur cure agents, azo-compounds, silanes (e.g., vinyl tri-ethoxy or vinyl tri-methoxy silane) , peroxides, and other types of radical generators (e.g. N-O break type and C-C break type) , among others.
- one or more coagents (co-activators) and/or accelerators can be used in combination with a crosslinking agent.
- suitable coagents include, but are not limited to multifunctional (meth) acrylate esters (e.g., trimethylolpropane triacrylate (TMPTA) ) dimaleimides, zinc salts of (meth) acrylic acid, allyl-containing cyanurates (e.g., triallyl cyanurate (TAC) ) , allyl-containing isocyanurates (e.g., triallyl isocyanurate (TAIC) ) , allyl-containing phthalates, homopolymers of dienes, and co-polymers of dienes and vinyl aromatics, among others.
- TMPTA trimethylolpropane triacrylate
- TAC triallyl cyanurate
- TAIC triallyl isocyanurate
- allyl-containing phthalates homopolymers of dienes, and co-polymers
- a coagent can be present in the thermally conductive composition in an amount ranging from 0.1 vol%to 0.8 vol%, based on the total volume of the composition.
- accelerators include, but are not limited to, sulfonamides, amines, disulfides, guanidines, thioureas, thazoles, thiurams, dithiocarbamates and xanthates, among others.
- Mineral oil can be included as a processing aid to facilitate compounding and ensure a workable mixture and good dispersion and also as a softness increasing agent, e.g., when a large quantity of filler is present in the composition.
- suitable mineral oils include paraffinic, naphthenic, and aromatic oils, among others.
- the composition comprises 10 to 40 vol%mineral oil, based on the total volume of the composition.
- antioxidants include, but are not limited to, hindered phenols, bisphenols, and thiobisphenols, and substituted hydroquinones, among others.
- coupling agents include, but are not limited to, silane coupling agents, titanate coupling agents, zirconium coupling agents, magnesium coupling agents and tin coupling agents, among others.
- plasticizers include, but are not limited to, phthalates, benzoates, dibenzoates, thermoplastic polyurethane plasticizers, phthalate esters, naphthalene sulfonate, trimellitates, adipates, sebacates, maleates, sulfonamides, organophosphates, and polybutene, among others.
- processing aids include, but are not limited to, waxes (e.g., polyethylene waxes, vegetable waxes, petroleum waxes) , metal salts of carboxylic acids (e.g., zinc stearate, calcium stearate, etc. ) , fatty acids (e.g., stearic acid, oleic acid, erucic acid, etc. ) , fatty amides (e.g., stearamide, etc. ) , polymers of ethylene oxide, copolymers of ethylene oxide and propylene oxide, nonionic surfactants, and polysiloxanes, among others. Processing aids can be used in amounts of 0.5 to 5.0 vol%.
- waxes e.g., polyethylene waxes, vegetable waxes, petroleum waxes
- metal salts of carboxylic acids e.g., zinc stearate, calcium stearate, etc.
- fatty acids e.g., stearic acid,
- Suitable flame retardants include, but are not limited to, magnesium hydroxide, aluminum trihydroxide (ATH) , calcium phosphate, titanium oxide, zinc oxide, magnesium carbonate, barium sulfate, barium borate, kaolinite, silica, antimony oxides, halocarbons, halogenated esters, halogenated ethers, brominated flame retardant agents, and halogen free compounds such as organophosphorus compounds, organonitrogen compounds, intumescent flame retardants, among others.
- the composition includes 10 to 30 vol%of one or more flame retardants, based on the total volume of elastomeric components in the composition.
- compositions can be prepared by conventional or hereafter discovered procedures that provide a mixture of the components as described herein, using equipment such as, but not limited to, mixers for melt blending of the components, and equipment used for continuous mixing procedures including single and twin screw extruders, static mixers, Farrel continuous mixer, as well as other machines and processes designed to disperse the components in intimate contact.
- equipment such as, but not limited to, mixers for melt blending of the components, and equipment used for continuous mixing procedures including single and twin screw extruders, static mixers, Farrel continuous mixer, as well as other machines and processes designed to disperse the components in intimate contact.
- the thermally conductive filler can be melt-mixed in an elastomer to make a filler-containing masterbatch.
- the elastomer used as the elastomeric matrix (continuous phase) is used to prepare the filler masterbatch.
- the filler loading in the masterbatch phase can be in the range of from 30 to 90 vol%, or from 40 to 85 vol%, or from 60 to 80 vol%.
- Melt mixing of the filler and the elastomer can be achieved by conventional or hereafter discovered melt-mixing procedures. For example, melt extrusion or mixing in a HAAKE melt mixer can be employed.
- the filler-containing masterbatch Once the filler-containing masterbatch has been prepared, it can then be added to the elastomer matrix component in an amount determined to provide the desired concentration of filler in the end product composition.
- the filler-containing masterbatch is melt-mixed with the elastomer matrix component of the continuous phase using a melt-mixing method. Additives, if employed, can be melt-mixed at any time, either in the masterbatch phase, the non-masterbatch phase, or the combined material.
- the combined vol%of the elastomeric matrix (continuous phase) (component A) , the crosslinked elastomeric discontinuous phase (component B) , the thermally conductive filler (component C) , in the composition is greater than or equal to ( ⁇ ) 95 vol%, or greater than or equal to 98 vol%, or greater than or equal to 99 vol%, of the total volume of the composition.
- the volume ratio of Component A to Component B is from 4: 5 to 15: 1. In embodiments, the volume ratio of Component A to Component C is from 1: 3 to 15: 4. In embodiments, the volume ratio of Component B to Component C is from 1: 12 to 5:4.
- the weight ratio of Component A to Component B is from 3: 7 to 26: 1.
- the weight ratio of Component A to Component C is from 1: 21 to 21: 8.
- the weight ratio of Component B to Component C is from 1: 84 to 7: 8.
- the thermally conductive composition has a thermal conductivity of greater than or equal to 0.5 Watts per meter per Kelvin (W/m ⁇ K) , or greater than or equal to 1.0, and up to 20, or up to 10, W/m ⁇ K.
- W/m ⁇ K Watts per meter per Kelvin
- the thermally conductive composition has a melting point of 30°C to 130°C, a Shore A hardness of 40 to 90, a Shore D hardness of 10 to 40, and a tensile modulus of 10 to 500 MPa.
- compositions may comprise a combination of two or more embodiments described herein.
- crosslinking agents include, but are not limited to, free radical initiators such as peroxides, azo compounds, silanes, and phenolic resins, among others.
- Organic initiators are preferred, such as any one of the peroxide initiators, such as dicumyl peroxide, di-tert-butyl peroxide, t-butyl perbenzoate, benzoyl peroxide, cumene hydroperoxide, t-butyl peroctoate, methyl ethyl ketone peroxide, 2, 5-dimethyl-2, 5-di (tert-butyl peroxy) hexane, 2, 5-dimethyl-2, 5-di (tert-butyl peroxy) -3-hexyne, lauryl peroxide, and tert-butyl peracetate, among others.
- Suitable azo compounds include 2, 2'-azobis (isobutyronitrile) , among others.
- Suitable vinyl silanes include vinyl trimethoxy
- a crosslinking agent can optionally be used in combination with one or more coagents (co-activators) and/or accelerators.
- the amount of crosslinking agent used can be in the range of 0.5 to 5 vol%, based on the total volume of the composition.
- Crosslinking temperatures are generally in the range of 50°C to 250°C.
- crosslinking can also be obtained by with irradiation (e.g., e-beam or x-ray radiation) or moisture, according to known techniques.
- irradiation e.g., e-beam or x-ray radiation
- moisture e.g., moisture, according to known techniques.
- the degree of crosslinking can be measured by dissolving the composition in a solvent (e.g., xylene or decalin) for a specified duration, and calculating the percent gel or unextractable component.
- Gel content can be determined according to ASTM D2765. In general, the percent gel typically increases with increasing crosslinking levels.
- the composition is crosslinked to a degree so as to provide a cured article having a percent gel content of at least 20 wt%, or at least 30 wt%, or at least 40 wt%, or at least 50 wt%, or at least 60 wt%, or at least 70 wt%, or at least 80 wt%, and up to 100 wt%, or up to 90 wt%, based on the total weight of the continuous phase elastomer matrix, as measured using xylene extractables.
- the thermally conductive filler is concentrated within the elastomer matrix (sea) continuous phase, with substantially no filler within the crosslinked elastomer (island) dispersed phase.
- the thermally conductive filler is concentrated within the elastomer matrix (sea) continuous phase, with substantially no filler within the crosslinked elastomer (island) dispersed phase.
- the crosslinked elastomer powder dispersed phase can act as an obstacle to interrupt the orientation of the thermally conductive filler (e.g., graphite) during processing before vulcanization (crosslinking) of the matrix elastomer.
- the thermally conductive filler e.g., graphite
- the orientation of the thermally conductive filler (e.g., graphite) within the elastomeric matrix continuous phase is controlled to achieve a high thermal conductivity (Tc) by the presence and interaction of a crosslinked elastomeric dispersed phase.
- Tc thermal conductivity
- a high amount of the thermally conductive filler e.g., graphite
- the thermally conductive material of the invention has a Tc that is twice the level as a thermally conductive material that does not include a crosslinked elastomeric dispersed phase in an island/sea structure as provided herein.
- a majority of the thermally conductive filler is oriented in a thickness direction of the material.
- the thermal conductivity (Tc) of the material is at least two times greater in the thickness direction than the same material but without the dispersed crosslinked elastomer domains.
- compositions of the present invention may be used to prepare a variety of articles of manufacture, or their component parts or portions thereof.
- the composition including a crosslinking agent can be fabricated into an article and the temperature raised to allow the crosslinking of the elastomer matrix (continuous phase) .
- the composition including a crosslinking agent can be fabricated into an article and exposed to a radiation source to allow crosslinking of the composition.
- inventive compositions may be processed into an article by any one of a number of conventional techniques and apparatus.
- Illustrative processes include, but are not limited to, injection molding, extrusion molding, thermoforming, compression molding, rotomolding, slush molding, over molding, insert molding, blow molding, calendering, and other processing techniques that are well known to those skilled in the art.
- Films, including multi-layer films, may be produced by cast or entering process, including blown film processes.
- Articles include, but are not limited to, sheets, molded goods and extruded parts. Additional articles include automotive parts, weather strips, belts, hoses, wire and cable jacketing and insulations including flame retardant versions, seals, O-rings, tire components, computer parts, building materials, electronic materials, among other applications.
- the crosslinked thermally conductive composition can be employed as a thermal interface material in a variety of articles of manufacture.
- the thermally conductive material can be employed in an article of manufacture comprising a heat-generating component, a heat-dissipating component, and a thermal interface material, where the thermal interface material is positioned so as to transfer heat from the heat-generating component to the heat-dissipating component, and where the thermal interface material comprises the above-described thermally conductive material.
- heat-generating components include, but are not limited to, microprocessors, central processing units, and graphics processors.
- An example of a heat-dissipating component includes, but is not limited to, a heat sink.
- the crosslinked thermally conductive composition can be employed as an elastomeric seal.
- Such seals can be used in telecommunication devices, pumps, valves, and the like.
- the seals can be any shape including O-rings, T-rings, gaskets, and the like.
- An article may comprise a combination of two or more embodiments described herein.
- the numerical ranges in this disclosure are approximate, and thus may include values outside of the range unless otherwise indicated. Numerical ranges include all values from and including the lower and the upper values, in increments of one unit, provided that there is a separation of at least two units between any lower value and any higher value. As an example, if a compositional, physical or other property, such as, for example, molecular weight, weight percentages, etc., is from 100 to 1,000, then the intent is that all individual values, such as 100, 101, 102, etc., and sub ranges, such as 100 to 144, 155 to 170, 197 to 200, etc., are expressly enumerated.
- aspect ratio refers to a ratio of an average value of the longest dimension to the average value of the shortest dimension.
- aspect ratio refers to a ratio of an average value of particle width or diameter (i.e., the longest dimension) to the average value of the particle thickness (i.e., the shortest dimension) .
- aspect ratio refers to a ratio of an average value of the particle length (i.e., the longest dimension) to the average value of the particle width or diameter (i.e., the shortest dimension) .
- the aspect ratio refers to the ratio between the long and short axes of the particle.
- compositions claimed through use of the term “comprising” may include any additional additive, adjuvant or compound, whether polymeric or otherwise, unless stated to the contrary.
- the term, “consisting essentially of” excludes from the scope of any succeeding recitation any other component, step or procedure, excepting those that are not essential to operability.
- the term “consisting of” excludes any component, step or procedure not specifically delineated or listed.
- Continuous phase is an art-recognized term meaning a component that disperses or suspends other components in a disperse or multi-phase system, also called “sea” phase (versus “island” phase) .
- Crosslinked, " "cured, “ and like terms, as used herein, refer to a composition or component of the composition that was subjected or exposed to a treatment which induced crosslinking to provide a composition or component having a gel content of 20 to 100 wt%insolubles.
- the degree of crosslinking may be measured according to ASTM 2765-84 by dissolving the composition or component in a solvent that dissolves the composition or component prior to crosslinking (e.g., xylene or decalene) for a specified duration, and calculating the percent gel or unextractable component.
- the percent gel content normally increases with increasing crosslinking levels.
- Elastomer and like terms, as used herein, denote a polymer having viscoelasticity. Generally, elastomers will have lower tensile modulus and higher failure strain relative to other materials, such as thermoplastics.
- ethylene-based interpolymer refers to a polymer that comprises, in polymerized of ethylene (based on the weight of the polymer) , and at least one comonomer.
- the "ethylene-based interpolymer” comprises a majority weight percent of ethylene (based on the weight of the interpolymer) .
- ethylene/ ⁇ -olefin interpolymer refers to a interpolymer that comprises, in polymerized form, ethylene, and at least an ⁇ -olefin. In one embodiment, the "ethylene/ ⁇ -olefin interpolymer" comprises a majority weight percent of ethylene (based on the weight of the interpolymer) .
- ethylene/ ⁇ -olefin copolymer refers to a copolymer that comprises, in polymerized form, a majority weight percent (wt%) of ethylene monomer (based on the weight of the copolymer) , and an ⁇ -olefin, as the only two monomer types.
- ethylene/ ⁇ -olefin/diene interpolymer refers to a polymer that comprises, in polymerized form, ethylene, at least an ⁇ -olefin, and a diene.
- the "ethylene/ ⁇ -olefin/diene interpolymer” comprises a majority weight percent of ethylene (based on the weight of the interpolymer) .
- the "ethylene/ ⁇ -olefin/diene interpolymer” comprising a majority weight percent of propylene (based on the weight of the interpolymer) .
- ethylene/ ⁇ -olefin/diene terpolymer refers to a polymer that comprises, in polymerized form, ethylene, an ⁇ -olefin, and a diene, as the only three monomer types.
- the "ethylene/ ⁇ -olefin/diene terpolymer” comprises a majority weight percent of ethylene (based on the weight of the terpolymer) .
- the "ethylene/ ⁇ -olefin/diene terpolymer” comprising a majority weight percent of propylene (based on the weight of the interpolymer) .
- Fiber particles and like terms, as used herein, refer to the particle in the form of threads, filaments or fibers, including twisted filaments as a single multiple-ply fiber, woven structures and other forms such as braids.
- Interpolymer and like terms, as used herein, mean a polymer prepared by the polymerization of at least two different types of monomers.
- the generic term interpolymer thus includes copolymers (employed to refer to polymers prepared from two different types of monomers) , and polymers prepared from more than two different types of monomers (e.g., terpolymers (three different monomer types) and tetrapolymers (four different monomer types) ) .
- Plate, “plate-like, and like terms, as used herein, refer to the morphology or shape of a particle as resembling a thin, flat plate or sheet.
- Polymer and like terms, as used herein, refer to a polymeric compound prepared by polymerizing monomers, whether of the same or a different type.
- the generic term polymer thus embraces the term homopolymer (employed to refer to polymers prepared from only one type of monomer, with the understanding that trace amounts of impurities can be incorporated into the polymer structure) and the term interpolymer as defined herein. Trace amounts of impurities, such as catalyst residues, can be incorporated into and/or within the polymer.
- Polylene-based polymer refers to a polymer that comprises, in polymerized form, a majority weight percent (wt%) of propylene monomer (based on the total weight of the polymer) , and, optionally, at least one comonomer.
- propylene-based interpolymer refers to a polymer that comprises, in polymerized form, a majority weight percent (wt%) of propylene monomer (based on the total weight of the polymer) , and at least one comonomer.
- Polylene/ ⁇ -olefin copolymer refers to a copolymer that comprises, in polymerized form, a majority amount of propylene monomer (based on the weight of the copolymer) , and an ⁇ -olefin, as the only two monomer types.
- sample CS3 made with silicone rubber as the sole matrix component had a higher Shore A hardness than TS2e test sample made with the EPDM/oil/silicone rubber matrix.
- Tc 2.12, 1.80 and 1.90 W/m ⁇ K, respectively
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Abstract
Description
Claims (15)
- A composition comprising at least the following:A) a continuous phase comprising an elastomer selected from the group consisting of an ethylene/α-olefin interpolymer, a propylene/α-olefin interpolymer, a propylene/ethylene interpolymer, and combinations thereof;B) a discontinuous phase comprising a crosslinked elastomer dispersed within the continuous phase, the crosslinked elastomer selected from the group consisting of a crosslinked ethylene/α-olefin interpolymer, a crosslinked propylene/α-olefin interpolymer, a crosslinked propylene/ethylene interpolymer, and combinations thereof; andC) a thermally conductive filler comprising a plurality of particles dispersed within the continuous phase.
- The composition of claim 1, wherein the composition has a thermal conductivity of ≥ 0.5 Watts per meter per Kelvin (W/mK) .
- The composition of claim 1 or claim 2, wherein the filler has a thermal conductivity of ≥ 20 Watts per meter per Kelvin (W/mK) .
- The composition of any one of the previous claims, wherein the filler is selected from the group consisting of graphite, aluminum, aluminum oxide, magnesium oxide, boron nitride, zinc oxide, silicon carbide, aluminum nitride, carbon fiber, silicon nitride, graphene nanoplatelets, zinc sulfide, and combinations thereof
- The composition of any one of the previous claims, wherein the filler has an aspect ratio of from 1:1 to 1:100.
- The composition of any one of the previous claims, wherein the particles of the filler are in a platy shape, a fibrous form, or a combination thereof.
- The composition of any one of the previous claims, wherein the elastomer of Component A has:a density of from 0.8 to 1.4 g/cc, anda Mooney Viscosity of from 5 to 150 (ML1+4, 125℃) .
- The composition of any one of the previous claims, wherein the elastomer of the Component A is an ethylene/α-olefin interpolymer.
- The composition of claim 8, wherein the ethylene/α-olefin interpolymer is ethylene/propylene/diene (EPDM) .
- The composition of any one of the previous claims, wherein Components A, B, C are present in an amount ≥ 95 wt%of the total weight of the composition.
- The composition of any one of the previous claims, wherein the thermally conductive filler of Component C is present in an amount of from 20 to 60 volume percent (vol%) based on the total volume of the composition.
- The composition of any one of the previous claims, whereinComponent A is present in an amount of 20 to 75 vol%, andComponent B is present in an amount of 5 to 25 vol%,based on the total volume of the composition.
- A crosslinked composition formed from the composition of any one of the previous claims.
- An article comprising at least one component formed from the composition of any one of the previous claims.
- The article of Claim 14, wherein the article is selected from the group consisting of thermal interface materials and elastomer seals.
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EP15895232.5A EP3310857B1 (en) | 2015-06-18 | 2015-06-18 | Thermally conductive elastomeric composites |
BR112017025325-9A BR112017025325B1 (en) | 2015-06-18 | 2015-06-18 | Composition, lattice composition and article |
JP2017562763A JP6681924B2 (en) | 2015-06-18 | 2015-06-18 | Thermally conductive elastomer composite |
CN201580080844.4A CN107636062B (en) | 2015-06-18 | 2015-06-18 | Heat-conducting elastic composite material |
PCT/CN2015/081738 WO2016201659A1 (en) | 2015-06-18 | 2015-06-18 | Thermally conductive elastomeric composites |
US15/735,465 US10351749B2 (en) | 2015-06-18 | 2015-06-18 | Thermally conductive elastomeric composites |
KR1020187000175A KR102388821B1 (en) | 2015-06-18 | 2015-06-18 | Thermally Conductive Elastomer Composite |
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EP3310857B1 (en) | 2022-06-22 |
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