WO2021200486A1 - 炭素含有アルミナ粉末、樹脂組成物、放熱部品、及び炭素含有アルミナ粉末の製造方法 - Google Patents
炭素含有アルミナ粉末、樹脂組成物、放熱部品、及び炭素含有アルミナ粉末の製造方法 Download PDFInfo
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- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- 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
- C09K5/08—Materials not undergoing a change of physical state when used
- C09K5/14—Solid materials, e.g. powdery or granular
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
- C01F7/00—Compounds of aluminium
- C01F7/02—Aluminium oxide; Aluminium hydroxide; Aluminates
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K9/00—Use of pretreated ingredients
- C08K9/04—Ingredients treated with organic substances
- C08K9/06—Ingredients treated with organic substances with silicon-containing compounds
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L101/00—Compositions of unspecified macromolecular compounds
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- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2004/00—Particle morphology
- C01P2004/30—Particle morphology extending in three dimensions
- C01P2004/32—Spheres
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2004/00—Particle morphology
- C01P2004/60—Particles characterised by their size
- C01P2004/61—Micrometer sized, i.e. from 1-100 micrometer
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2006/00—Physical properties of inorganic compounds
- C01P2006/12—Surface area
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
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- C01P2006/80—Compositional purity
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
- C08K2003/2227—Oxides; Hydroxides of metals of aluminium
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K2201/00—Specific properties of additives
- C08K2201/001—Conductive additives
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/2039—Modifications to facilitate cooling, ventilating, or heating characterised by the heat transfer by conduction from the heat generating element to a dissipating body
Definitions
- the present invention relates to a carbon-containing alumina powder, a resin composition, heat-dissipating parts, and a method for producing a carbon-containing alumina powder.
- a sheet formed by filling silicone rubber with an inorganic powder having good electrical insulation and thermal conductivity for example, an inorganic powder such as boron nitride powder, aluminum nitride powder, and alumina powder, or Asuka-C hardness
- an inorganic powder such as boron nitride powder, aluminum nitride powder, and alumina powder, or Asuka-C hardness
- a heat sink is attached via a heat radiating component such as a flexible sheet of 25 or less (for example, Patent Document 1).
- the quality of heat dissipation in the resin composition after the molding process is greatly affected by the thermal conductivity of the resin composition after the molding process and the adhesion to the adherend (shape followability), and is also included in the resin composition. It is also affected by the presence or absence of voids (air layer). Thermal conductivity is ensured by filling the inorganic powder in a high proportion, but when the inorganic powder is filled in a resin or the like in a high proportion, the fluidity of the resin composition before the molding process is significantly reduced, so that the molding process is performed. The property is impaired and the adhesion is significantly reduced.
- Japanese Unexamined Patent Publication No. 9-296114 Japanese Unexamined Patent Publication No. 2000-1616 Japanese Unexamined Patent Publication No. 11-209618
- the spherical alumina powder surface-treated with the alkoxysilane compound thickens when the resin is filled with the spherical alumina powder because of its high specific surface area, low average sphericity, and a distorted shape.
- high filling of particles is difficult. Therefore, the moldability is low, and the thermal conductivity of the obtained heat-dissipating component is also low.
- the molded product obtained by filling the resin with the spherical alumina powder has a problem that the tackiness is low and the adhesion (shape followability) to the adherend is not sufficient.
- the present invention has been made in view of such a problem, and is a carbon-containing alumina powder capable of suppressing an increase in viscosity when filled in a resin and realizing high thermal conductivity of a resin composition containing the resin, and a carbon-containing alumina powder thereof.
- An object of the present invention is to provide a resin composition containing carbon-containing alumina powder and heat-dissipating parts.
- the present inventors can suppress an increase in viscosity when filling a resin by using a carbon-containing alumina powder containing specific carbon-containing alumina particles.
- a carbon-containing alumina powder containing specific carbon-containing alumina particles We have found that it is possible to realize high thermal conductivity of a resin composition containing a resin and to improve the adhesion of the resin composition to an adherend, and have completed the present invention.
- the present invention is as follows.
- the carbon content A in the carbon-containing alumina powder and 3 g of the carbon-containing alumina powder were washed twice with 50 mL of acetone at room temperature for 5 minutes each and held at 100 ° C. for 240 minutes, and then in the alumina powder.
- the ratio B / A is calculated using the carbon content B.
- Each of the carbon contents is a value measured by a carbon / sulfur simultaneous analyzer.
- the carbon according to [1] which contains a silicon atom and a carbon atom, and has a ratio MSi / MC of the mass MSi of the silicon atom to the mass MC of the carbon atom of 0.1 or more and 1.2 or less. Containing alumina powder.
- [5] The method for producing a carbon-containing alumina powder according to [1] or [2], wherein the alkoxysilane compound and the alumina powder are mixed, and the relative humidity at room temperature is 20% or more and 60% or less.
- a method for producing a carbon-containing alumina powder which comprises a step of heating at a temperature of 100 ° C. or higher and 150 ° C. or lower and a heating time of 0.5 hours or more and 1.5 hours or less.
- a carbon-containing alumina powder capable of suppressing an increase in viscosity when filled in a resin and realizing high thermal conductivity of the resin composition containing the resin, and a resin composition containing the carbon-containing alumina powder and heat dissipation. Parts can be provided.
- the present embodiment a mode for carrying out the present invention (hereinafter, simply referred to as “the present embodiment”) will be described in detail.
- the following embodiments are examples for explaining the present invention, and the present invention is not limited to the present embodiment.
- the alumina powder of this embodiment contains specific carbon-containing alumina particles.
- Carbon-containing alumina powder (Carbon-containing alumina particles)
- the carbon-containing alumina particles according to the present embodiment are particularly limited as long as they are carbon-containing alumina particles and have a diameter equivalent to a circle of projected area by a microscope, an average sphericity, and a specific surface area within the range described later. Not done.
- the carbon-containing alumina particles can be obtained, for example, by treating the surface of the alumina particles with an alkoxysilane compound under specific conditions.
- Examples of the alkoxysilane compound usually include four types of alkoxysilane compounds having 1 to 4 alkoxy groups and oligomers obtained by condensing them.
- Examples of the four types of alkoxysilane compounds include tetraalkoxysilane compounds, trialkoxysilane compounds, dialkoxysilane compounds, and monoalkoxysilane compounds, and those in which a hydrogen atom is not directly bonded to a silicon atom are preferable. These alkoxysilane compounds can be used alone or in admixture of two or more.
- tetraalkoxysilane compound examples include tetramethoxysilane, tetraethoxysilane, tetrapropoxysilane, tetraisopropoxysilane, and tetrabutoxysilane.
- trialkoxysilane compound examples include methyltrimethoxysilane, methyltriethoxysilane, methyltripropoxysilane, methyltributoxysilane, methyltriphenoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, propyltrimethoxysilane, and butyltrimethoxy.
- dialkoxysilane compound examples include dimethyldimethoxysilane, dimethyldiethoxysilane, dimethyldipropoxysilane, dibutyldimethoxysilane, dipropyldimethoxysilane, phenylmethyldimethoxysilane, phenylmethyldiethoxysilane, diphenyldimethoxysilane, and diphenyldiethoxysilane.
- Examples thereof include cyclohexylmethyldimethoxysilane and vinylmethyldimethoxysilane.
- Examples of the monoalkoxysilane compound include trimethylmethoxysilane, triethylmethoxysilane, triphenylmethoxysilane, diethylvinylmethoxysilane, dimethylpropylmethoxysilane, dimethylphenylmethoxysilane, diphenylmethylmethoxysilane, trimethylethoxysilane, triethylethoxysilane, and triphenyl. Examples thereof include ethoxysilane, dimethylvinylethoxysilane, dimethylpropylethoxysilane, and dimethylphenylethoxysilane.
- the carbon-containing alumina particles according to the present embodiment are spherical, it becomes difficult to thicken the resin when the alumina powder is filled, and therefore the resin can be highly filled. Therefore, the diameter equivalent to the projected area circle by the microscope method is 1 ⁇ m. It is 100 ⁇ m or less and the average sphericity is 0.85 or more. The average sphericity is preferably 0.85 or more and 0.99 or less. When the average sphericity is in the above range, the fluidity of the carbon-containing alumina particles in the resin can be further improved, and the increase in viscosity when the resin is filled with the carbon-containing alumina powder can be suppressed.
- the average sphericity is measured by the following microscopy. That is, the particle image taken by a scanning electron microscope, a transmission electron microscope, or the like is taken into an image analyzer, and the projected area (SA) and the peripheral length (PM) of the particles are measured from the photograph. Assuming that the area of a perfect circle having the same perimeter as the perimeter (PM) is (SB), the sphericity of the particle is SA / SB.
- the sphericity of 200 arbitrary particles having a projected area circle-equivalent diameter of 1 ⁇ m or more and 100 ⁇ m or less is obtained as described above, and the arithmetic mean value thereof is taken as the average sphericity.
- the specific measurement method is as described in the examples.
- the projected area circle-equivalent diameter refers to the diameter of a perfect circle having the same projected area as the projected area (SA) of the particles.
- the specific surface area of the carbon-containing alumina particles according to the present embodiment is 0.05 m 2 / g or more 1 because a resin composition and a heat-dissipating material can be obtained in which the contact resistance at the interface with the resin is low and the viscosity is less likely to increase. .0m and 2 / g or less, preferably not more than 0.1 m 2 / g or more 0.6 m 2 / g.
- the specific surface area is measured by the BET flow method, and the specific measuring method is as described in the examples.
- the carbon-containing alumina powder according to this embodiment has a ratio B / A of 0.20 or more and 0.90 or less calculated by using the following measuring method.
- the ratio B / A is 0.20 or more, the effect that the carbon-containing substance such as the surface treatment agent remaining in the carbon-containing alumina powder suppresses bleeding from the resin composition or the heat radiating component can be obtained. ..
- the ratio B / A is 0.90 or less, it is difficult to thicken the resin when it is filled in the resin, and it is easy to mold the resin.
- the ratio B / A is determined by washing the carbon content A in the carbon-containing alumina powder according to the present embodiment and 3 g of the carbon-containing alumina powder twice at room temperature with 50 mL of acetone for 5 minutes each, and 240 at 100 ° C. It is calculated using the carbon content B in the alumina powder after holding for a minute.
- the carbon contents A and B are values measured by a carbon / sulfur simultaneous analyzer. The specific measurement method is as described in the examples.
- the carbon-containing alumina powder according to the present embodiment satisfies the above range of the ratio B / A, it is possible to suppress an increase in viscosity when the resin is filled with the carbon-containing alumina powder, and the adhesion to the adherend is good. Resin composition and heat-dissipating parts can be obtained.
- the ratio B / A is 0.20 or more means that a substance (for example, an alkoxysilane compound) containing carbon in a predetermined ratio or more on the surface of the carbon-containing alumina particles in the carbon-containing alumina powder is, for example, chemical. It means that it is firmly fixed by the bond.
- the strongly adhered carbon-containing substance contributes to the adhesion to the adherend, so that a resin composition and heat-dissipating parts having good adhesion can be obtained.
- the fact that the ratio B / A is 0.90 or less means that a substance containing carbon in a predetermined ratio or less (for example, an alkoxysilane compound) exists in the carbon-containing alumina powder in a state where it can be easily removed. It means that it is. It is presumed that such a carbon-containing substance can improve the fluidity between the resin and the carbon-containing alumina particles and suppress the increase in viscosity when the resin is filled.
- the substance containing carbon is an alkoxysilane compound
- the surface of the alumina particles is treated with the alkoxysilane compound, not all of the alkoxysilane compounds react with the alumina particles, and the unreacted alkoxysilane compound is generated. Remains.
- the unreacted residual amount of the alkoxysilane compound is so small that the ratio B / A is 0.20 or more, the unreacted alkoxysilane compound is suppressed from bleeding from the resin composition, and the adherend. It is estimated that the adhesion to (shape followability) will be improved.
- the residual alkoxysilane compound contributes to the fluidity between the resin and the carbon-containing alumina powder, and has the effect of improving the adhesion between the resin and the alumina particles. Therefore, the present inventors consider that it is important that the alkoxysilane compound remains to some extent. That is, when the unreacted residual amount of the alkoxysilane compound is so large that the ratio B / A is 0.90 or less, when the carbon-containing alumina powder is highly filled in the resin or the like, the resin composition before the molding process is formed. It is estimated that the fluidity is improved, the molding processability is maintained, and the adhesion is improved.
- the ratio B / A calculated by using the above measurement method has better adhesion, better fluidity between the resin and the carbon-containing alumina powder, and from the viewpoint of suppressing thickening. It is preferably 0.20 or more and 0.90 or less, and more preferably 0.30 or more and 0.70 or less.
- the carbon-containing alumina powder according to the present embodiment contains a silicon atom and a carbon atom, and the ratio of the mass MSi of the silicon atom to the mass MC of the carbon atom (hereinafter, also simply referred to as “mass ratio”) MSi /.
- the MC is preferably 0.1 or more and 1.2 or less from the viewpoint of the fixing rate of the treatment agent on the alumina surface.
- the silicon atom and carbon atom are derived from, for example, the alkoxysilane compound used for the surface treatment of the alumina powder, may be derived from the alkoxysilane compound that has reacted with the surface of the alumina powder, and remain on the surface of the alumina powder.
- the mass ratio MSi / MC is preferably 0.1 or more and 1.2 or less, and more preferably 0.2 or more and 0.4 or less, from the viewpoint of the fixing rate of the treatment agent on the alumina surface.
- the mass ratio MSi / MC is measured by, for example, an energy dispersive X-ray analyzer (EDX). That is, it can be obtained from the ratio of the X-ray counts of the Si element and the C element.
- EDX energy dispersive X-ray analyzer
- the content of the carbon-containing alumina particles in the carbon-containing alumina powder is preferably 10% by mass or more, more preferably 50% by mass or more, from the viewpoint of modifying the surface of the alumina particles. .. More preferably, it may be 70% by mass or more and 90% by mass or more. The upper limit may be 100% by mass or less, 10% by mass or less, 30% by mass or less, and 50% by mass or less.
- the method for producing the carbon-containing alumina powder of the present embodiment includes a step of mixing the alkoxysilane compound and the alumina powder (hereinafter, also referred to as “mixing step”) and a relative humidity of 20% or more and 60% or less at room temperature. It has a step of heating at a temperature of 100 ° C. or higher and 150 ° C. or lower and a heating time of 0.5 hours or longer and 1.5 hours or lower (hereinafter, also referred to as “heating step”).
- alkoxysilane compound as a raw material examples include the above-mentioned four types of alkoxysilane compounds having 1 to 4 alkoxy groups, oligomers obtained by condensing them, and the like. Among these, a trialkoxysilane compound and a dialkoxysilane compound are preferable from the viewpoint of reacting well with the alumina powder. These alkoxysilane compounds can be used alone or in admixture of two or more.
- alumina powder As the raw material alumina powder, a known alumina powder containing alumina particles having an average sphericity of 0.85 or more can be used.
- the raw material alumina powder preferably contains alumina particles having an average particle size of 1 ⁇ m or more and 100 ⁇ m or less.
- the average particle size refers to the median diameter (d50) based on the volume.
- the average particle size of the alumina particles can be measured by, for example, a laser light diffraction scattering type particle size distribution measuring machine (“Model LS-230” (trade name) manufactured by Beckman Coulter).
- the measurement solution is prepared by adding alumina particles to ethanol and dispersing the measurement solution with a known stirrer such as a homogenizer for about 1 minute so that the display of the concentration adjustment window of the apparatus becomes 45% or more and 55% or less. Obtained by preparing.
- the raw material alumina powder preferably contains alumina particles having an average spherical degree of alumina particles having a projected area circle-equivalent diameter of 1 ⁇ m or more and 100 ⁇ m or less by microscopy and having an average sphericity of 0.85 or more.
- the average sphericity is preferably 0.90 or more and 0.98 or less from the viewpoint of suppressing thickening when the resin is filled.
- the average sphericity is measured by the above-mentioned microscopy method, and the specific measuring method is as described in Examples.
- the diameter equivalent to the projected area circle by the above microscopy is less than 10 ⁇ m.
- the proportion of alumina particles having a sphericity of 0.85 or less is preferably 1.0% or less on a number basis, and more preferably 0.5% or less on a number basis.
- the lower limit is, for example, 0.1% on a number basis.
- Alumina particles contained in the alumina powder of the raw material, its specific surface area, because it can widely contact area of the interface between the alkoxysilane compound is preferably from 0.05 m 2 / g or more 1.0 m 2 / g, More preferably, it is 0.1 m 2 / g or more and 0.5 m 2 / g or less.
- 0.1 part by mass or more and 3.0 parts by mass or less, preferably 0.2 parts by mass or more and 1.0 part by mass or less of the hydrolyzed solution in which methanol, ethanol and water are dissolved in a solvent is added.
- the solvent water is preferable in terms of dispersibility, safety and economy, but a flammable liquid such as alcohol and a mixed liquid such as water-alcohol may be used as long as the raw materials can be dispersed.
- a mixing method for example, a predetermined amount of the raw material and the solvent may be added and mixed with a stirrer or the like until the mixture is sufficiently dispersed.
- the mixed solution obtained as described above has a relative humidity of 20% or more and 60% or less at room temperature (25 ° C.), a temperature of 100 ° C. or more and 150 ° C. or less, and a heating time of 0. Heat for 5 hours or more and 1.5 hours or less.
- the alkoxysilane compound reacts with the alumina particles, and the carbon-containing alumina powder according to the present embodiment is obtained.
- the relative humidity is 20% or more, the alkoxysilane compound is hydrolyzed by the surface-adsorbed water of the alumina particles, and the effect of easily reacting with the OH groups on the alumina surface can be obtained.
- the temperature is 100 ° C. or higher, the effect that the reaction easily proceeds can be obtained.
- the temperature is 150 ° C. or lower, the boiling point of the alkoxysilane is not reached before the reaction, and a decrease in the reaction amount can be suppressed.
- the obtained carbon-containing alumina particles may be used as they are as the carbon-containing alumina powder according to the present embodiment.
- the carbon-containing alumina powder according to the present embodiment can be obtained by subjecting the obtained carbon-containing alumina particles to a classification treatment, a sieving treatment, or the like.
- the resin composition according to the present embodiment contains at least a resin and a carbon-containing alumina powder according to the present embodiment.
- the resin composition according to the present embodiment can suppress thickening and has high thermal conductivity, and is a molded product such as a heat-dissipating part obtained from the resin composition. It is possible to improve the adhesion to the adherend.
- thermoplastic resin various polymer compounds such as thermoplastic resin and its oligomers and elastomers can be used.
- epoxy resin phenol resin, melamine resin, urea resin, unsaturated polyester, urethane resin, acrylic resin, and Fluororesin
- Polyamides such as polyimide, polyamideimide, and polyetherimide
- Polyethylene such as polybutylene terephthalate and polyethylene terephthalate
- Polyphenylene sulfide aromatic polyester, polysulfone, liquid crystal polymer, polyether sulfone, polycarbonate, maleimide modified resin, ABS (Acrylonitrile / butadiene / styrene) resin, AAS (acrylonitrile / acrylic rubber / styrene) resin, AES (acrylonitrile / ethylene / propylene / diene rubber / styrene) resin, EVA (ethylene vinyl acetate copolymer) resin, silicone resin, silicone resin, silicone
- epoxy resin epoxy resin, phenol resin, urethane resin, acrylic resin, fluororesin, polyimide, polyphenylene sulfide, polycarbonate, ABS resin, and silicone resin are preferable from the viewpoint of heat resistant temperature, strength, and hardness after curing.
- Silicone resin, epoxy resin, urethane resin, and acrylic resin are more preferable, and silicone resin is further preferable.
- the silicone resin it is preferable to use a rubber or gel obtained from a one-component or two-component addition reaction type liquid silicone having an organic group such as a methyl group and a phenyl group.
- a rubber or gel obtained from a one-component or two-component addition reaction type liquid silicone having an organic group such as a methyl group and a phenyl group.
- examples of such rubbers or gels include "YE5822A solution / YE5822B solution” manufactured by Momentive Performance Materials Japan GK and "SE1885A solution / SE1885B solution” manufactured by Toray Dow Corning. Can be done.
- the content of the carbon-containing alumina powder according to the present embodiment is 30% by mass or more and 97% by mass or less with respect to the total amount of the resin composition from the viewpoint of expressing the characteristics of the filler to be filled. It is preferably 50% by mass or more and 95% by mass or less. Since the carbon-containing alumina powder according to the present embodiment is difficult to thicken even when filled in the resin, it is possible to suppress the thickening of the resin composition even if it is contained in the resin composition within the above range. Is.
- the content of the carbon-containing alumina powder is 50% by mass or more, it tends to be easy to obtain a resin composition and heat-dissipating parts capable of achieving good thermal conductivity and adhesion to an adherend.
- the resin content for binding the carbon-containing alumina powder can be secured, and the heat-dissipating component can be more preferably used.
- the content of the resin according to the present embodiment is 3% by mass or more and 70% by mass or less with respect to the total amount of the resin composition from the viewpoint of expressing the characteristics of the filler to be filled. It is preferable, and it is more preferable that it is 5% by mass or more and 50% by mass or less.
- the resin composition of the present embodiment contains fused silica, crystalline silica, zircon, and silicic acid, if necessary, as long as the characteristics of the present embodiment are not impaired.
- Inorganic fillers such as calcium, calcium carbonate, silicon carbide, aluminum nitride, boron nitride, beryllia, and zirconia; nitrogen-containing compounds such as melamine and benzoguanamine, oxazine ring-containing compounds, and phosphate compounds of phosphorus compounds, aromatic condensed phosphorus.
- Flame-retardant compounds such as acid esters and halogen-containing condensed phosphoric acid esters; additives and the like may be contained.
- Additives include reaction retarders such as dimethyl maleate, curing agents, curing accelerators, flame retardants, flame retardants, colorants, tackifiers, UV absorbers, antioxidants, optical brighteners, and light. Examples thereof include sensitizers, thickeners, lubricants, defoaming agents, surface conditioners, brighteners, and polymerization inhibitors. These components may be used alone or in admixture of two or more. In the resin composition of the present embodiment, the content of other components is usually 0.1% by mass or more and 5.0% by mass or less, respectively.
- Examples of the method for producing the resin composition of the present embodiment include a method of sufficiently stirring the resin, the carbon-containing alumina powder, and other components as needed.
- a predetermined amount of each component is blended with a blender, a Henschel mixer or the like, kneaded with a heating roll, a kneader, a uniaxial or biaxial extruder or the like, cooled, and then pulverized.
- the heat radiating component according to the present embodiment includes the carbon-containing alumina powder or the resin composition according to the present embodiment.
- the heat radiating component according to the present embodiment can realize high thermal conductivity, that is, can have high heat radiating property.
- the adhesion to the adherend can be improved.
- the content of the carbon-containing alumina powder in the heat-dissipating component according to the present embodiment is preferably 30% by volume or more and 85% by volume or less from the viewpoint of achieving higher thermal conductivity and adhesion to the adherend.
- heat-dissipating parts include heat-dissipating sheets, heat-dissipating grease, heat-dissipating spacers, semiconductor encapsulants, heat-dissipating paints (heat-dissipating coating agents), heat-dissipating potting agents, heat-dissipating gap fillers, and the like.
- the measurement of the specific surface area is a value based on the BET method, and carbon obtained in Examples and Comparative Examples using a specific surface area measuring machine "Macsorb HM model-1208 (trade name)" manufactured by Mountech Co., Ltd.
- the specific surface area (m 2 / g) was measured by the BET one-point method using 1.0 g of each of the contained alumina particles.
- each of the carbon-containing alumina particles obtained in Examples and Comparative Examples was heated at 300 ° C. and 5 minutes in a nitrogen gas atmosphere as a pretreatment. Further, in the BET measurement, a mixed gas of 30% nitrogen and 70% helium was used as the adsorbed gas, and the flow rate was adjusted so that the indicated value of the main body flow meter was 25 ml / min.
- Ratio B / A of carbon content A and carbon content B in carbon-containing alumina powder was measured using a carbon / sulfur simultaneous analyzer (CS-444LS type (trade name) manufactured by LECO), and the carbon content A was quantified by the calibration curve method. .. Specifically, after obtaining a calibration curve using carbon steel having a known carbon content as a standard substance, each of the carbon-containing alumina powders obtained in Examples and Comparative Examples was used together with iron powder and tungsten powder as a combustion improver.
- Mass ratio MSi / MC For the mass ratio MSi / MC of silicon atom and carbon atom, 0.1 g of each of the carbon-containing alumina particles obtained in Examples and Comparative Examples was added to Energy Dispersive X-ray Analyzer (EDX) (Hitachi High Technologies). From the count ratio of C and Si on the particle surface when measured using a desktop microscope MiniscopeTM3030Plus) under the conditions of an acceleration voltage of 15 kV, an energy range of 10 to 40 keV, a number of channels of 1024 to 4096, and a spectrum collection of 20 sec. The mass ratios of each were calculated to obtain the mass ratio MSi / MC.
- EDX Energy Dispersive X-ray Analyzer
- Viscosity Silicone rubber A liquid (vinyl group-containing polymethylsiloxane, YE5822A liquid manufactured by Momentive Performance Materials Japan LLC (trade name)) is used to combine the carbon-containing alumina powders obtained in Examples and Comparative Examples. ), The carbon-containing alumina powder (filling rate of alumina powder: 87.9% by mass) after being left for one day is added and mixed using a stirrer (NZ-1100 (trade name) manufactured by Tokyo Rika Kikai Co., Ltd.). , Vacuum defoaming to give the composition.
- a stirrer NZ-1100 (trade name) manufactured by Tokyo Rika Kikai Co., Ltd.
- the viscosity (Pa ⁇ s) of the obtained composition was determined using a B-type viscometer type (TVB-10 (trade name) manufactured by Toki Sangyo Co., Ltd.). The viscosity was measured using a No. 7 spindle at a rotation speed of 20 rpm and a room temperature of 20 ° C.
- Thermal conductivity Silicone rubber A liquid (vinyl group-containing polymethylsiloxane, YE5822A liquid (trade name) manufactured by Momentive Performance Materials Japan LLC), which was obtained in Examples and Comparative Examples, respectively.
- the blending ratio thereof was 0.01 part by volume with respect to 100 parts by volume of the silicone rubber mixed solution obtained by mixing 10 parts by volume of the silicone rubber A solution with 1 part by volume of the silicone rubber B solution. It was calculated by adding the maximum filling amount of the alumina powder obtained in Examples and Comparative Examples to the liquid to which the reaction retarder was added, and the ratio was shown in Table 1.
- the obtained slurry-like sample was poured into a mold provided with a recess having a diameter of 28 mm and a thickness of 3 mm, degassed, and then heat-molded at 150 ° C. for 20 minutes.
- the obtained molded product was sandwiched between a copper heater case of 15 mm ⁇ 15 mm and a copper plate, and set with a tightening torque of 5 kgf / cm. Then, 15 W of electric power was applied to the copper heater case and the case was held for 4 minutes, the temperature difference between the copper heater case and the copper plate was measured, and the thermal resistance was calculated by the following formula.
- Thermal resistance (° C / W) Temperature difference between copper heater case and copper plate (° C) / Heater power (W)
- the thermal conductivity is calculated from the following formula. Was calculated. That is, the thermal conductivity is a value when each of the carbon-containing alumina powders obtained in Examples and Comparative Examples is filled with the maximum filling amount that can be heat-molded.
- ARC-TC-1 type trade name manufactured by Agne Co., Ltd. was used.
- Thermal conductivity (W / m ⁇ K) molded body thickness (m) / ⁇ thermal resistance (° C / W) x heat transfer area (m 2 ) ⁇
- Example 1 As an alkoxysilane compound, 0.5 parts by mass of hexyltrimethoxysilane (KBM-3063 manufactured by Shin-Etsu Chemical Co., Ltd.), 0.5 parts by mass of methanol, and 0.1 parts by mass of water were mixed in this order for 2 days at room temperature. A hydrolyzate was prepared with stirring. Next, an alumina powder having an average particle diameter of 45 ⁇ m (DAW-45 manufactured by Denka Co., Ltd. (trade name), an alumina particle having a projected area circle equivalent diameter of 1 ⁇ m or more and 100 ⁇ m or less by microscopy) has an average sphericalness of 0.90 and a specific surface area of 0.
- Example 2 As shown in Table 2, a carbon-containing alumina powder containing carbon-containing alumina particles was obtained in the same manner as in Example 1 except that the relative humidity and the heating temperature were changed. The physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 2.
- Example 3 As the alkoxysilane compound, N-decyltrimethoxysilane (KBM-3103C (trade name) manufactured by Shin-Etsu Chemical Co., Ltd.) was used instead of hexyltrimethoxysilane, and the relative humidity and heating temperature shown in Table 2 were changed. Obtained a carbon-containing alumina powder containing carbon-containing alumina particles in the same manner as in Example 1. The physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 2.
- Example 4 As the alkoxysilane compound, dimethyldimethoxysilane (KBM-22 (trade name) manufactured by Shin-Etsu Chemical Co., Ltd.) was used instead of hexyltrimethoxysilane, and the relative humidity and heating temperature shown in Table 2 were changed.
- a carbon-containing alumina powder containing carbon-containing alumina particles was obtained in the same manner as in Example 1. The physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 2.
- Example 5 As the alumina powder, instead of DAW-45 (trade name) manufactured by Denka Co., Ltd., an alumina powder having an average particle diameter of 3 ⁇ m (DAW-03 (trade name) manufactured by Denka Co., Ltd., with a projected area circle equivalent diameter of 1 ⁇ m or more and 100 ⁇ m or less by microscopy). Carbon in the same manner as in Example 1 except that the average sphericity of certain alumina particles: 0.90, specific surface area: 0.7 m 2 / g) was used, and the relative humidity and heating temperature were changed as shown in Table 2. A carbon-containing alumina powder containing containing alumina particles was obtained. The physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 2.
- Example 6 As the alumina powder, instead of DAW-45 (trade name) manufactured by Denka Co., Ltd., an alumina powder having an average particle diameter of 90 ⁇ m (DAW-90 (trade name) manufactured by Denka Co., Ltd., with a projected area circle equivalent diameter by microscopy of 1 ⁇ m or more and 100 ⁇ m or less.
- DAW-45 trade name
- DAW-90 trade name
- Table 2 A carbon-containing alumina powder containing carbon-containing alumina particles was obtained.
- the physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 2.
- Example 7 First, alumina LS-21 (trade name) manufactured by Nippon Light Metal Co., Ltd. was melted, cooled, and crushed in an arc furnace to prepare a pulverized fused alumina product. The crushing treatment was performed with a ball mill, and alumina balls were used as the crushing medium. The obtained pulverized alumina product was classified into alumina powder (average particle size: 0.2 ⁇ m, average sphericity of alumina particles having a projected area circle equivalent diameter of 1 ⁇ m or more and 100 ⁇ m or less by microscopic method: 0.75, specific surface area: 0.2 m 2 / g) was prepared.
- alumina powder average particle size: 0.2 ⁇ m, average sphericity of alumina particles having a projected area circle equivalent diameter of 1 ⁇ m or more and 100 ⁇ m or less by microscopic method: 0.75, specific surface area: 0.2 m 2 / g
- alumina powder and the alumina powder having an average particle diameter of 45 ⁇ m (DAW-45 (trade name) manufactured by Denka Co., Ltd., the average sphericalness of alumina particles having a projected area circle equivalent diameter of 1 ⁇ m or more and 100 ⁇ m or less by microscopy:
- Alumina powder was obtained by appropriately mixing with 0.90, specific surface area: 0.2 m 2 / g).
- a carbon-containing alumina powder containing carbon-containing alumina particles was obtained in the same manner as in Example 1 except that this alumina powder was used and the relative humidity and heating temperature were changed as shown in Table 2.
- Table 2 The physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 2.
- alumina powder instead of DAW-45 (trade name) manufactured by Denka Co., Ltd., an alumina powder having an average particle diameter of 120 ⁇ m (DAW-120 (trade name) manufactured by Denka Co., Ltd.) has a projected area circle equivalent diameter of 1 ⁇ m or more and 100 ⁇ m or less by microscopy.
- the average sphericity of certain alumina particles: 0.90, specific surface area: 0.03 m 2 / g) was used, and the relative humidity and heating temperature shown in Table 3 were changed, but in the same manner as in Example 1.
- a carbon-containing alumina powder containing carbon-containing alumina particles was obtained.
- the physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 3.
- alumina powder instead of DAW-45 (trade name) manufactured by Denka Co., Ltd., an alumina powder having an average particle diameter of 1 ⁇ m (DAW-01 manufactured by Denka Co., Ltd. (trade name), the equivalent diameter of the projected area circle by microscopy is 1 ⁇ m or more and 100 ⁇ m or less.
- the average sphericity of certain alumina particles: 0.90, specific surface area: 1.2 m 2 / g) was used, and the relative humidity and heating temperature shown in Table 3 were changed, but in the same manner as in Example 1.
- a carbon-containing alumina powder containing carbon-containing alumina particles was obtained.
- the physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 3.
- alumina LS-21 (trade name) manufactured by Nippon Light Metal Co., Ltd. was melted, cooled, and crushed in an arc furnace to prepare a pulverized fused alumina product.
- the crushing treatment was performed with a ball mill, and alumina balls were used as the crushing medium.
- the obtained pulverized alumina product was classified into alumina powder (average particle size: 0.2 ⁇ m, average sphericity of alumina particles having a projected area circle equivalent diameter of 1 ⁇ m or more and 100 ⁇ m or less by microscopic method: 0.75, specific surface area: 0.2 m 2 / g) was prepared.
- alumina powder and the alumina powder having an average particle diameter of 45 ⁇ m (DAW-45 (trade name) manufactured by Denka Co., Ltd., the average sphericalness of alumina particles having a projected area circle equivalent diameter of 1 ⁇ m or more and 100 ⁇ m or less by microscopy:
- Alumina powder was obtained by appropriately mixing with 0.90, specific surface area: 0.2 m 2 / g).
- a carbon-containing alumina powder containing carbon-containing alumina particles was obtained in the same manner as in Example 1 except that this alumina powder was used and the relative humidity and heating temperature were changed as shown in Table 3.
- Table 3 The physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 3.
- Example 4 A carbon-containing alumina powder containing carbon-containing alumina particles was obtained in the same manner as in Example 1 except that the relative humidity was changed from 50% to 15%. The physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 3.
- Example 5 A carbon-containing alumina powder containing carbon-containing alumina particles was obtained in the same manner as in Example 1 except that the relative humidity was changed from 50% to 70%. The physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 3.
- Example 6 A carbon-containing alumina powder containing carbon-containing alumina particles was obtained in the same manner as in Example 1 except that the heating temperature was changed from 140 ° C. to 80 ° C. The physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 3.
- Example 7 A carbon-containing alumina powder containing carbon-containing alumina particles was obtained in the same manner as in Example 1 except that the heating temperature was changed from 140 ° C. to 170 ° C. The physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 3.
- Example 8 A carbon-containing alumina powder containing carbon-containing alumina particles was obtained in the same manner as in Example 1 except that the heating time was changed from 1.0 hour to 0.3 hours. The physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 3.
- Example 9 A carbon-containing alumina powder containing carbon-containing alumina particles was obtained in the same manner as in Example 1 except that the heating time was changed from 1.0 hour to 2.0 hours. The physical properties of the obtained carbon-containing alumina particles and carbon-containing alumina powder were evaluated. The results are shown in Table 3.
- the carbon-containing alumina powder according to the present embodiment and the resin composition using the alumina powder can be applied to various uses, but a heat radiating sheet, a heat radiating grease, a heat radiating spacer, a semiconductor encapsulant, and a heat radiating paint (heat radiating coating agent). ), Heat-dissipating potting agent, heat-dissipating gap filler, and other heat-dissipating parts. Further, these heat-dissipating parts can be suitably used for personal computers, automobiles, portable electronic devices, household electric appliances and the like.
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Abstract
Description
また、樹脂にこの球状アルミナ粉末を充填して得られた成形品では、タック性が低いため、被着物への密着性(形状追従性)が十分ではないとの問題を有する。
[1]顕微鏡法による投影面積円相当径が1μm以上100μm以下である炭素含有アルミナ粒子を含む炭素含有アルミナ粉末であって、前記炭素含有アルミナ粒子の平均球形度が、0.85以上であり、かつ、比表面積が0.05m2/g以上1.0m2/g以下であり、かつ、下記の測定方法を用いて算出された、前記炭素含有アルミナ粉末中の炭素含有率Aに対する炭素含有率Bの比B/Aが、0.20以上0.90以下である、炭素含有アルミナ粉末。
(測定方法)
前記炭素含有アルミナ粉末中の前記炭素含有率Aと、前記炭素含有アルミナ粉末3gをアセトン50mLを用いて室温で5分間ずつ2回洗浄し、100℃で240分間保持した後の前記アルミナ粉末中の前記炭素含有率Bとを用いて、前記比B/Aを算出する。各前記炭素含有率は、炭素/硫黄同時分析計によって測定された値である。
[3]樹脂と、[1]又は[2]に記載の炭素含有アルミナ粉末とを含む、樹脂組成物。
[4][1]若しくは[2]に記載の炭素含有アルミナ粉末、又は[3]に記載の樹脂組成物を含む、放熱部品。
[5][1]又は[2]に記載の炭素含有アルミナ粉末の製造方法であって、アルコキシシラン化合物と、アルミナ粉末とを混合する工程と、室温下での相対湿度20%以上60%以下、温度100℃以上150℃以下、かつ加熱時間0.5時間以上1.5時間以下で加熱する工程とを有する、炭素含有アルミナ粉末の製造方法。
(炭素含有アルミナ粒子)
本実施形態に係る炭素含有アルミナ粒子は、炭素を含有するアルミナ粒子であって、後述の範囲内の顕微鏡による投影面積円相当径、平均球形度、及び比表面積を有するものであれば、特に限定されない。炭素含有アルミナ粒子は、例えば、アルコキシシラン化合物でアルミナ粒子の表面を特定の条件で処理することで得られる。
本実施形態に係る炭素含有アルミナ粉末は、下記の測定方法を用いて算出された比B/Aが0.20以上0.90以下である。比B/Aが、0.20以上であると、炭素含有アルミナ粉末中に残留する表面処理剤等の炭素を含む物質が、樹脂組成物又は放熱部品からのブリードを抑制するという効果が得られる。一方、比B/Aが、0.90以下であると、樹脂に充填した際に増粘し難く、かつ、成形加工し易いという効果が得られる。(測定方法)
上記比B/Aは、本実施形態に係る炭素含有アルミナ粉末中の炭素含有率Aと、上記炭素含有アルミナ粉末3gをアセトン50mLを用いて室温で5分間ずつ2回洗浄し、100℃で240分間保持した後のアルミナ粉末中の炭素含有率Bとを用いて算出される。炭素含有率A及びBは、炭素/硫黄同時分析計によって測定された値である。具体的な測定方法は、実施例に記載のとおりである。
上記比B/Aが0.20以上であるということは、炭素含有アルミナ粉末中の炭素含有アルミナ粒子の表面に所定の割合以上の炭素を含む物質(例えば、アルコキシシラン化合物)が、例えば、化学結合により強く固着していることを意味する。この場合、その強く固着した炭素を含む物質が被着物への密着性に寄与することで、その密着性が良好な樹脂組成物及び放熱部品を得ることができると考えられる。一方、上記比B/Aが0.90以下であるということは、炭素含有アルミナ粉末中に、所定の割合以下の炭素を含む物質(例えばアルコキシシラン化合物)が、容易に除去できる状態で存在していることを意味する。このような炭素を含む物質は、樹脂と炭素含有アルミナ粒子との間の流動性を向上させ、樹脂に充填する際に粘度上昇を抑制できると推定している。
質量比MSi/MCは、例えば、エネルギー分散型X線分析装置(EDX)により測定される。即ち、Si元素とC元素のX線カウント数の比から求めることができる。
本実施形態において、炭素含有アルミナ粉末中における炭素含有アルミナ粒子の含有率は、アルミナ粒子表面の改質の観点から、10質量%以上であることが好ましく、50質量%以上であることがより好ましい。さらに好ましくは70質量%以上、90質量%以上であってよい。上限については100質量%以下、10質量%以下、30質量%以下、50質量%以下であってよい。
本実施形態の炭素含有アルミナ粉末の製造方法は、アルコキシシラン化合物と、アルミナ粉末とを混合する工程(以下、「混合工程」ともいう。)と、室温下での相対湿度20%以上60%以下、温度100℃以上150℃以下、かつ加熱時間0.5時間以上1.5時間以下で加熱する工程(以下、「加熱工程」ともいう。)とを有する。
本実施形態に係る炭素含有アルミナ粉末を得るための原料としては、アルコキシシラン化合物と、アルミナ粉末と、必要に応じて、メタノール、エタノール、及び水とを用いる。
球形度が低いアルミナ粒子が含まれると、炭素含有アルミナ粉末の球形度も低くなり、樹脂に充填した際に増粘する傾向がある点から、上記の顕微鏡法による投影面積円相当径が10μm未満であるアルミナ粒子の球形度が0.85以下であるアルミナ粒子の割合が、個数基準で1.0%以下であることが好ましく、個数基準で0.5%以下であることがより好ましい。下限は、例えば、個数基準で0.1%である。
本実施形態の炭素含有アルミナ粉末の製造方法において、まず、混合工程では、アルコキシシラン化合物と、アルミナ粉末と、必要に応じて、メタノールと、エタノールと、水とを混合して、混合液を得る。本実施形態では、アルコキシシラン化合物と、アルミナ粉末との反応が進行しやすく、未反応のアルコキシシラン化合物が過剰にならないよう抑制する観点から、アルミナ粉末100質量部に、アルコキシシラン化合物と、必要に応じて、メタノールと、エタノールと、水とを溶媒に溶解させた加水分解液0.1質量部以上3.0質量部以下を、好ましくは0.2質量部以上1.0質量部以下を添加して、混合することが好ましい。溶媒としては、水が、分散性、安全性及び経済性の点で好ましいが、原料を分散させることができれば、アルコール等の可燃性液体、及び水-アルコール等の混合液でもあってもよい。混合方法は、例えば、原料と溶媒とを所定量投入し、十分分散するまで撹拌機等で混合すればよい。
本実施形態に係る樹脂組成物は、少なくとも、樹脂と、本実施形態に係る炭素含有アルミナ粉末とを含む。本実施形態に係る樹脂組成物は、上記炭素含有アルミナ粉末を含むことにより、増粘を抑制できると共に高い熱伝導性を有し、しかもその樹脂組成物から得られる放熱部品のような成形品の被着物への密着性を良好にすることが可能となる。
樹脂としては、熱可塑性樹脂及びそのオリゴマー、エラストマー類等の種々の高分子化合物を用いることでき、例えば、エポキシ樹脂、フェノール樹脂、メラミン樹脂、ユリア樹脂、不飽和ポリエステル、ウレタン樹脂、アクリル樹脂、及びフッ素樹脂;ポリイミド、ポリアミドイミド、及びポリエーテルイミド等のポリアミド;ポリブチレンテレフタレート、及びポリエチレンテレフタレート等のポリエステル;ポリフェニレンスルフィド、芳香族ポリエステル、ポリスルホン、液晶ポリマー、ポリエーテルスルホン、ポリカーボネート、マレイミド変性樹脂、ABS(アクリロニトリル・ブタジエン・スチレン)樹脂、AAS(アクリロニトリル・アクリルゴム・スチレン)樹脂、AES(アクリロニトリル・エチレン・プロピレン・ジエンゴム・スチレン)樹脂、EVA(エチレン酢酸ビニル共重合体)樹脂、及びシリコーン樹脂等を用いることができる。これらの樹脂は、1種単独で、又は2種以上を適宜混合して用いることができる。
本実施形態の樹脂組成物において、充填するフィラーの特性発現の点から、その樹脂組成物の全量に対して、本実施形態に係る炭素含有アルミナ粉末の含有量が30質量%以上97質量%以下であることが好ましく、50質量%以上95質量%以下であることがより好ましい。本実施形態に係る炭素含有アルミナ粉末は、樹脂に充填しても増粘し難いので、上記の範囲内で樹脂組成物中に含まれても、樹脂組成物の増粘を抑制することが可能である。また、炭素含有アルミナ粉末の含有量が50質量%以上であると、良好な高熱伝導化及び被着物への密着性を実現できる樹脂組成物及び放熱部品を得ることが容易になる傾向にあり、95質量%以下であると、炭素含有アルミナ粉末を結着する樹脂分を確保でき、放熱部品により好適に用いることができる。
本実施形態の樹脂組成物には、本実施形態の特性が損なわれない範囲において、本実施形態に係る炭素含有アルミナ粉末及び樹脂以外に、必要に応じて、溶融シリカ、結晶シリカ、ジルコン、珪酸カルシウム、炭酸カルシウム、炭化珪素、窒化アルミニウム、窒化ホウ素、ベリリア、及びジルコニア等の無機充填材;メラミン及びベンゾグアナミン等の窒素含有化合物、オキサジン環含有化合物、及びリン系化合物のホスフェート化合物、芳香族縮合リン酸エステル、及び含ハロゲン縮合リン酸エステル等の難燃性の化合物;添加剤等を含んでもよい。添加剤としては、マレイン酸ジメチル等の反応遅延剤、硬化剤、硬化促進剤、難燃助剤、難燃剤、着色剤、粘着付与剤、紫外線吸収剤、酸化防止剤、蛍光増白剤、光増感剤、増粘剤、滑剤、消泡剤、表面調整剤、光沢剤、及び重合禁止剤等が挙げられる。これらの成分は、1種単独で、又は2種以上を適宜混合して用いることができる。本実施形態の樹脂組成物において、その他の成分の含有率は、通常、それぞれ0.1質量%以上5.0質量%以下である。
本実施形態の樹脂組成物の製造方法は、例えば、樹脂と、炭素含有アルミナ粉末と、必要に応じてその他の成分を十分に攪拌して得る方法が挙げられる。本実施形態の樹脂組成物は、例えば、各成分の所定量を、ブレンダー及びヘンシェルミキサー等によりブレンドした後、加熱ロール、ニーダー、及び一軸又は二軸押し出し機等によって混練し、冷却後、粉砕することによって製造することができる。
本実施形態に係る放熱部品は、本実施形態に係る炭素含有アルミナ粉末、又は樹脂組成物を含む。本実施形態に係る放熱部品は、上記炭素含有アルミナ粉末又は樹脂組成物を用いることで、高い熱伝導性を実現できる、すなわち、高い放熱性を有することができる。さらに、本実施形態に係る放熱部品は、上記炭素含有アルミナ粉末又は樹脂組成物を用いることで、被着物への密着性を良好にすることができる。本実施形態に係る放熱部品中の炭素含有アルミナ粉末の含有率は、より高い熱伝導性及び被着物への密着性を実現できる点から、30体積%以上85体積%以下であることが好ましく、40体積%以上83体積%以下であることがより好ましい。放熱部品としては、例えば、放熱シート、放熱グリース、放熱スペーサー、半導体封止材、放熱塗料(放熱コート剤)、放熱ポッティング剤、放熱ギャップフィラー等が挙げられる。
(1)炭素含有アルミナ粉末の平均球形度
上記の顕微鏡法のとおり、走査型電子顕微鏡(SEM)(日本電子社製JSM-6301F型)にて撮影した粒子像を画像解析装置(マウンテック社製「MacView」(商品名))に取り込み、写真から、実施例及び比較例にて得られた炭素含有アルミナ粒子のそれぞれの粒子(顕微鏡法による投影面積円相当径が1μm以上100μm以下)の投影面積(A)と周囲長(PM)を任意に200個測定した。それらの値を用いて、個々の粒子の球形度及びその割合を求め、また、個々の粒子の球形度の相加平均値を平均球形度とした。
比表面積の測定は、BET法に基づく値であり、マウンテック社製比表面積測定機「Macsorb HM model-1208(商品名)」を用い、実施例及び比較例で得られた炭素含有アルミナ粒子のそれぞれ1.0gを用い、BET一点法にて、比表面積(m2/g)を測定した。なお、測定に先立ち、前処理として、実施例及び比較例にて得られた炭素含有アルミナ粒子のそれぞれについて、窒素ガス雰囲気中で300℃、及び5分間加熱を行った。また、BET測定において、吸着ガスには、窒素30%、及びヘリウム70%の混合ガスを用い、本体流量計の指示値が25ml/minになるように流量を調整した。
まず、炭素/硫黄同時分析計(LECO社製CS-444LS型(商品名))を用いて、炭素含有アルミナ粉末中における炭素量を測定し、検量線法にて、炭素含有率Aを定量した。具体的には、炭素含有量が既知の炭素鋼を標準物質として検量線を求めた後、実施例及び比較例で得られた炭素含有アルミナ粉末のそれぞれを鉄粉や助燃材であるタングステン粉末と共に、酸素雰囲気下で、アルコキシシラン化合物が完全に分解し、全炭素がCO2に変換されるまで酸化燃焼し、生成したCO2量を赤外検出器で測定して、炭素含有率Aを求めた。
続いて、実施例及び比較例で得られた炭素含有アルミナ粉末のそれぞれ3gを、アセトン50mLを用いて室温(25℃)で5分間ずつ2回洗浄し、100℃で240分間保持し、アルミナ粉末を得た。炭素/硫黄同時分析計(LECO社製CS-444LS型(商品名))を用いて、このアルミナ粉末中における炭素量を測定し、検量線法にて、炭素含有率Bを定量した。検量線法の測定は、上記と同様の方法で行った。
得られた炭素含有率Aと、炭素含有率Bとを用いて、比B/Aを算出した。
ケイ素原子と炭素原子との質量比MSi/MCは、実施例及び比較例にて得られた炭素含有アルミナ粒子のそれぞれの0.1gを、エネルギー分散型X線分析装置(EDX)(日立ハイテクノロジーズ社製卓上顕微鏡MiniscopeTM3030Plus)を用いて、加速電圧15kV、エネルギー範囲10~40keV、チャンネル数1024~4096、スペクトル収集20secの条件の範囲にて測定した際の、粒子表面のCとSiのカウント比よりそれぞれの質量比を算出して、質量比MSi/MCを求めた。
実施例及び比較例にて得られたそれぞれの炭素含有アルミナ粉末をシリコーンゴムA液(ビニル基含有ポリメチルシロキサン、モメンティブ・パフォーマンス・マテリアルズ・ジャパン合同会社製YE5822A液(商品名))に、1日放置後の炭素含有アルミナ粉末(アルミナ粉末の充填率:87.9質量%)を投入し、撹拌機(東京理化器械社製NZ-1100(商品名))を用いて混合し、真空脱泡して組成物を得た。得られた組成物について、B型粘度計型(東機産業社製TVB-10(商品名))を用いて、粘度(Pa・s)を求めた。粘度測定は、No7スピンドルを使用し、回転数は20rpm、室温20℃で行った。
シリコーンゴムA液(ビニル基含有ポリメチルシロキサン、モメンティブ・パフォーマンス・マテリアルズ・ジャパン合同会社製YE5822A液(商品名))に、実施例及び比較例にて得られたそれぞれの炭素含有アルミナ粉末と、反応遅延剤(マレイン酸ジメチル、関東化学社製)と、シリコーンゴムB液(モメンティブ・パフォーマンス・マテリアルズ・ジャパン合同会社製YE5822B液(商品名)、架橋剤等を含む)とを順に投入し、攪拌した後、脱泡処理をして、スラリー状試料を得た。なお、これらの配合比は、シリコーンゴムA液10体積部に、シリコーンゴムB液1体積部の割合で混合して得られたシリコーンゴム混合液100質量部に対して、0.01質量部の反応遅延剤を加えた液体に、実施例及び比較例にて得られたアルミナ粉末を加熱成形可能な最大充填量を加えることで算出され、表1に示される割合であった。
熱抵抗(℃/W)=銅製ヒーターケースと銅板との温度差(℃)/ヒーター電力(W)
次いで、熱抵抗(℃/W)、伝熱面積[銅製ヒーターケースの面積](m2)、及び締め付けトルク5kgf/cm時の成形体厚(m)を用いて、下記の式から熱伝導率を算出した。すなわち、熱伝導率は、実施例及び比較例にて得られた炭素含有アルミナ粉末のそれぞれを加熱成形可能な最大充填量で充填したときの値である。なお、熱伝導率測定装置としては、アグネ社製ARC-TC-1型(商品名)を用いた。
熱伝導率(W/m・K)=成形体厚(m)/{熱抵抗(℃/W)×伝熱面積(m2)}
アルコキシシラン化合物として、ヘキシルトリメトキシシラン(信越化学社製KBM-3063)0.5質量部と、メタノール0.5質量部と、水0.1質量部とをこの順に混合し、室温で2日攪拌して加水分解液を調製した。
次いで、平均粒子径45μmアルミナ粉末(デンカ社製DAW-45(商品名)、顕微鏡法による投影面積円相当径が1μm以上100μm以下であるアルミナ粒子の平均球形度:0.90、比表面積:0.2m2/g)100質量部に対して、1.0質量部の加水分解液を添加後、混合機(日本アイリッヒ社製EL-1(商品名))で約5分間混合攪拌し、室温で1日放置した。
その後、室温(25℃)下での相対湿度50%、温度140℃にて、1.0時間加熱処理を行い、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表2に示す。
表2に記載のとおり、相対湿度、及び加熱温度を変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表2に示す。
アルコキシシラン化合物として、ヘキシルトリメトキシシランの代わりに、N-デシルトリメトキシシラン(信越化学社製KBM-3103C(商品名))を用い、かつ、表2に示す相対湿度及び加熱温度に変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表2に示す。
アルコキシシラン化合物として、ヘキシルトリメトキシシランの代わりに、ジメチルジメトキシシラン(信越化学社製KBM-22(商品名))を用い、かつ、表2に示す相対湿度及び加熱温度に変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表2に示す。
アルミナ粉末として、デンカ社製DAW-45(商品名)に代えて、平均粒子径3μmアルミナ粉末(デンカ社製DAW-03(商品名)、顕微鏡法による投影面積円相当径が1μm以上100μm以下であるアルミナ粒子の平均球形度:0.90、比表面積:0.7m2/g)を用い、かつ、表2に示す相対湿度及び加熱温度に変更した以外、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表2に示す。
アルミナ粉末として、デンカ社製DAW-45(商品名)に代えて、平均粒子径90μmアルミナ粉末(デンカ社製DAW-90(商品名)、顕微鏡法による投影面積円相当径が1μm以上100μm以下であるアルミナ粒子の平均球形度:0.90、比表面積:0.06m2/g)を用い、かつ、表2に示す相対湿度及び加熱温度に変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表2に示す。
まず、日本軽金属(株)社製アルミナLS-21(商品名)をアーク炉で溶融、冷却、及び粉砕して電融アルミナ粉砕物を調製した。なお、粉砕処理はボールミルで行い、粉砕メディアにはアルミナボールを用いた。得られたアルミナ粉砕物を分級処理によりアルミナ粉末(平均粒子径:0.2μm、顕微鏡法による投影面積円相当径が1μm以上100μm以下であるアルミナ粒子の平均球形度:0.75、比表面積:0.2m2/g)を調製した。
続いて、得られたアルミナ粉末と、平均粒子径45μmアルミナ粉末(デンカ社製DAW-45(商品名)、顕微鏡法による投影面積円相当径が1μm以上100μm以下であるアルミナ粒子の平均球形度:0.90、比表面積:0.2m2/g)と適宜混合し、アルミナ粉末を得た。このアルミナ粉末を用い、かつ、表2に示す相対湿度及び加熱温度に変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表2に示す。
アルミナ粉末として、デンカ社製DAW-45(商品名)に代えて、平均粒子径120μmアルミナ粉末(デンカ社製DAW-120(商品名)、顕微鏡法による投影面積円相当径が1μm以上100μm以下であるアルミナ粒子の平均球形度:0.90、比表面積:0.03m2/g)を用い、かつ、表3に示す相対湿度及び加熱温度に変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表3に示す。
アルミナ粉末として、デンカ社製DAW-45(商品名)に代えて、平均粒子径1μmアルミナ粉末(デンカ社製DAW-01(商品名)、顕微鏡法による投影面積円相当径が1μm以上100μm以下であるアルミナ粒子の平均球形度:0.90、比表面積:1.2m2/g)を用い、かつ、表3に示す相対湿度及び加熱温度に変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表3に示す。
まず、日本軽金属(株)社製アルミナLS-21(商品名)をアーク炉で溶融、冷却、及び粉砕して電融アルミナ粉砕物を調製した。なお、粉砕処理はボールミルで行い、粉砕メディアにはアルミナボールを用いた。得られたアルミナ粉砕物を分級処理によりアルミナ粉末(平均粒子径:0.2μm、顕微鏡法による投影面積円相当径が1μm以上100μm以下であるアルミナ粒子の平均球形度:0.75、比表面積:0.2m2/g)を調製した。
続いて、得られたアルミナ粉末と、平均粒子径45μmアルミナ粉末(デンカ社製DAW-45(商品名)、顕微鏡法による投影面積円相当径が1μm以上100μm以下であるアルミナ粒子の平均球形度:0.90、比表面積:0.2m2/g)と適宜混合し、アルミナ粉末を得た。このアルミナ粉末を用い、かつ、表3に示す相対湿度及び加熱温度に変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表3に示す。
相対湿度を50%から15%に変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表3に示す。
相対湿度を50%から70%に変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表3に示す。
加熱温度を140℃から80℃に変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表3に示す。
加熱温度を140℃から170℃に変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表3に示す。
加熱時間を1.0時間から0.3時間に変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表3に示す。
加熱時間を1.0時間から2.0時間に変更した以外は、実施例1と同様にして、炭素含有アルミナ粒子を含む炭素含有アルミナ粉末を得た。得られた炭素含有アルミナ粒子及び炭素含有アルミナ粉末の物性を評価した。その結果を表3に示す。
Claims (5)
- 顕微鏡法による投影面積円相当径が1μm以上100μm以下である炭素含有アルミナ粒子を含む炭素含有アルミナ粉末であって、前記炭素含有アルミナ粒子の平均球形度が、0.85以上であり、かつ、比表面積が0.05m2/g以上1.0m2/g以下であり、かつ、
下記の測定方法を用いて算出された、前記炭素含有アルミナ粉末中の炭素含有率Aに対する炭素含有率Bの比B/Aが、0.20以上0.90以下である、炭素含有アルミナ粉末。(測定方法)
前記炭素含有アルミナ粉末中の前記炭素含有率Aと、前記炭素含有アルミナ粉末3gをアセトン50mLを用いて室温で5分間ずつ2回洗浄し、100℃で240分間保持した後の前記アルミナ粉末中の前記炭素含有率Bとを用いて、前記比B/Aを算出する。各前記炭素含有率は、炭素/硫黄同時分析計によって測定された値である。 - ケイ素原子と炭素原子とを含み、前記ケイ素原子の質量MSiと前記炭素原子の質量MCとの比MSi/MCが0.1以上1.2以下である、請求項1に記載の炭素含有アルミナ粉末。
- 樹脂と、請求項1又は2に記載の炭素含有アルミナ粉末とを含む、樹脂組成物。
- 請求項1若しくは2に記載の炭素含有アルミナ粉末、又は請求項3に記載の樹脂組成物を含む、放熱部品。
- 請求項1又は2に記載の炭素含有アルミナ粉末の製造方法であって、
アルコキシシラン化合物と、アルミナ粉末とを混合する工程と、
室温下での相対湿度20%以上60%以下、温度100℃以上150℃以下、かつ加熱時間0.5時間以上1.5時間以下で加熱する工程とを有する、炭素含有アルミナ粉末の製造方法。
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EP21778936.1A EP4129909A4 (en) | 2020-03-31 | 2021-03-24 | CARBON ALUMINUM OXIDE POWDER, RESIN COMPOSITION, HEAT DISSIPATION COMPONENT AND METHOD FOR PRODUCING CARBON ALUMINUM OXIDE POWDER |
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