Composite body having high thermal conductivity and method of making the composite body

Patent metadata

Field	Value
Publication number	US-2023123580-A1
Application number	US-202218046883-A
Country	US
Kind code	A1
Filing date	Oct 14, 2022
Priority date	Oct 14, 2021
Publication date	Apr 20, 2023
Grant date	—

Abstract

A composite article can comprise a composite body including an organic polymer and ceramic particles comprising hexagonal boron nitride (hBN) particles distributed throughout the organic polymer, wherein an amount of the hBN particles ranges from 40 vol % to 90 vol % based on a total volume of the body; and the body comprises an in plane thermal conductivity of at least 15 W/mK. The hBN particles within the composite body can have a March-Dollase Orientation parameter η of at least 50%.

First claim

1 . A composite article comprising: a composite body including an organic polymer and ceramic particles comprising hexagonal boron nitride (hBN) particles distributed throughout the organic polymer, wherein
an amount of the hBN particles ranges from 40 vol % to 90 vol % based on a total volume of the composite body; at least 90 vol % of the ceramic particles are hBN particles; and the composite body comprises an in plane thermal conductivity of at least 13.5 W/mK.

2 . The composite article of claim 1 , wherein an in-plane March-Dollase orientation parameter η of the hBN particles within the composite body is at least 50%.

3 . The composite article of claim 1 , wherein the in-plane thermal conductivity of the composite body is at least 16.0 W/mK.

4 . The composite article of claim 1 , wherein an average aspect ratio of length to thickness of the hBN particles is at least 5.

5 . The composite article of claim 1 , wherein the hBN particles have an average particle size (D50) of at least 1 micron and not greater than 100 microns.

6 . The composite article of claim 1 , wherein the hBN particles comprise a multi-modal particle distribution.

7 . The composite article of claim 6 , wherein the hBN particles comprise a bi-modal particle distribution.

8 . The composite article of any one of claim 6 , wherein a particle size distribution of the hBN particles includes a first peak having a first peak maximum and a second peak having a second peak maximum, and an intensity ratio of the first peak maximum to the second peak maximum at least 2:1 and not greater than 10:1.

9 . The composite article of claim 6 , wherein a distance between the first peak maximum and the second peak maximum is at least 20 microns and not greater than 70 microns.

10 . The composite article of claim 6 , wherein the first peak maximum corresponds to a particles size in a range of 8 microns to 13 microns, and the second peak maximum corresponds to a particle size in a range of 35 to 50 microns.

11 . The composite article of claim 6 , wherein a difference between the average particle size (D50) and the mean particle size of the hBN particles is at least 5 microns.

12 . The composite article of claim 6 , wherein an eighty percent distribution value (D90-D10) of the hBN particles is at least 15 microns and not greater than 80 microns.

13 . The composite article of claim 1 , wherein an electric volume resistivity of the composite body is at least 1.0 E+12; or at least 1.0 E+13, or at least 1.0 E+14.

14 . The composite article of claim 1 , wherein the organic polymer of the composite body includes a thermoplastic polymer or a thermoset polymer.

15 . The composite article of claim 14 , wherein the organic polymer includes a silicone polymer, an acrylate polymer, a polyurethane, an epoxide polymer, a polyamide, a polyimide, a liquid crystalline polymer (LCP), a fluoropolymer, a polyethylene, a polypropylene, a polystyrene, a polyester, a polycarbonate, a polybutylene terephthalate (PBT), a polyethylene terephthalate (PET), a polyamide, a liquid crystalline polymer (LCP), a polyacrylonitrile (PAN), a polyether ether ketone (PEEK), a polyetherketoneketone (PEKK), a polysulfone, a polyethersulfone, a polyphenylene oxide (PPO), a polyetherimide, a thermoplastic elastomer (TPE, olefinic or styrenic), a polyvinylidene fluoride (PVDF), a perfluoroalkoxy alkane (PFA), a fluorinated ethylene propylene (FEP), an ethylene tetrafluoroethylene (ETFE), or any copolymer thereof, or any combination thereof.

16 . The composite article of claim 14 , wherein the organic polymer includes a silicone polymer.

17 . The composite article of claim 1 , wherein the ceramic particles of the composite boy consist essentially of hBN particles.

18 . The composite article of claim 1 , wherein the composite body further comprises a surfactant.

19 . The composite article of claim 1 , wherein the composite body is a sheet having a thickness of at least 25 microns and not greater than 5000 microns.

20 . A method of forming a composite article, comprising:
preparing a mixture of ceramic particles and an organic polymer, wherein the ceramic particles comprise at least 90 vol % hBN particles based on the total volume of the ceramic particles, and an amount of the hBN particles ranges from 40 vol % to 90 vol % based on a total volume of the mixture; applying a layer of the mixture to a mold or a support; conducting an alignment procedure of the hBN particles; and solidifying and/or curing the organic polymer to form a composite body, wherein an in-plane thermal conductivity of the composite body is at least 13.5 W/mK.

Assignees

• Saint Gobain Ceramics

Inventors

• Wang Hua
• Liang Shuai
• Watkins Nicholas
• Bazant Martin Z
• Plain Sarah Elizabeth
• Li Chuanping
• Hampden-Smith Mark
• Kamath Mithun N
• Shrives Daniel

Classifications

• C08K2201/016

  Additives defined by their aspect ratio · CPC title

• C08K2201/003

  Additives being defined by their diameter · CPC title

• C08K2201/014

  Additives containing two or more different additives of the same subgroup in C08K · CPC title

• C08K2003/385

  Binary compounds of nitrogen with boron · CPC title

• C08K3/38

  Boron-containing compounds · CPC title