Thermal interface material and method of making and using the same

Patent metadata

Field	Value
Publication number	US-9353304-B2
Application number	US-200913254683-A
Country	US
Kind code	B2
Filing date	Dec 22, 2009
Priority date	Mar 2, 2009
Publication date	May 31, 2016
Grant date	May 31, 2016

Abstract

A thermal interface material comprises a polymeric elastomer material, a thermally conductive filler, and a coupling agent, along with other optional components. In one exemplary heat transfer material, a coupling agent having the formula:

where Y is either a cyclic structure or Y is represented by Formula II:

where:
a=1 or 2
b=2 or 3
R 1 contains at least one of a neoalkoxy group, an ether group, or a C2-C30 straight or branched alkyl, alkenyl, alkynyl, aralkyl, aryl, or alkaryl group
R′ 2 and R″ 2 are independently selected from Hydrogen, a neoalkoxy group, an ether group, and a C2-C30 straight or branched alkyl, alkenyl, alkynyl, aralkyl, aryl, or alkaryl group
X=Group four transition metal; and
where a=1, R 3 contains at least one of a neoalkoxy group, an ether group, or a C2-C30 straight or branched alkyl, alkenyl, alkynyl, aralkyl, aryl, or alkaryl group; or
where a=2, the two R 3 groups independently contain at least one of a neoalkoxy group, an ether group, or a C2-C30 straight or branched alkyl, alkenyl, alkynyl, aralkyl, aryl, or alkaryl groups or the two R 3 groups together form an alkyldiolato group
and, if Y is a cyclic structure, X is a member of the cyclic structure and the cyclic structure also contains a pyrophosphate group such as Formula II shown above.

First claim

The invention claimed is:

1. A heat transfer material comprising:
about 3 wt. % to about 14 wt. % of a polymeric elastomer material;
a wax, wherein the wax comprises less than about 10 wt. % of the heat transfer material;
about 80 wt. % to about 95 wt. % of a thermally conductive filler; and
about 0.3 wt. % to about 2 wt. % of a coupling agent selected from the group consisting of: titanium IV 2,2 (bis 2-propenolatomethyl)butanolato, tris(dioctyl)pyrophosphato-O; zirconium IV 2,2 (bis 2-propenolatomethyl)butanolato, tris(diisooctyl)pyrophosphato-O; titanium IV bis(dioctyl)pyrophosphato-O, oxoethylenediolato, adduct, bis(dioctyl) (hydrogen)phosphite-O; and zirconium IV 2,2-bis(2-propenolatomethyl)butanolato, cyclo di[2,2-(bis 2-propenolatomethyl)butanolato], pyrophosphato-O,O.

2. The material of claim 1 , wherein the polymeric elastomer material comprises hydrogenated polybutadiene.

3. The material of claim 1 , wherein the thermally conductive filler comprises particles of a metal selected from the group consisting of: silver, aluminum, copper and alloys thereof.

4. The material of claim 3 , wherein the thermally conductive filler comprises particles of aluminum.

5. The material of claim 1 , wherein the coupling agent is titanium IV 2,2 (bis 2-propenolatomethyl)butanolato, tris(dioctyl)pyrophosphato-O.

6. The material of claim 5 , wherein the material comprises from about 0.5 wt. % to about 1 wt. % of the coupling agent.

7. The material of claim 5 , wherein the material comprises from about 0.5 wt. % to about 0.7 wt. % of the coupling agent.

8. The material of claim 5 , wherein the material comprises:
from about 5 wt. % to about 10 wt. % of the polymeric elastomer material;
from about 1 wt. % to about 5 wt. % of the wax;
from about 85 wt. % to about 92 wt. % of the thermally conductive filler; and
from about 0.5 wt. % to about 1 wt. % of the coupling agent.

9. The material of claim 5 , wherein the polymer elastomer material comprises a material selected from the group consisting of: an ethylene-propylene rubber, a polyethylene/butylene, a polyethylene-butylene-styrene, a polyethylene-propylene-styrene, a hydrogenated polyalkyldiene mono-ol, a hydrogenated polyalkyldiene diol, a hydrogenated polyisoprene, polyolefin elastomer, and blends thereof.

10. The material of claim 5 , wherein the polymer elastomer material comprises a hydrogenated polybutadiene mono-ol.

11. The material of claim 5 , further comprising an amine resin that is crosslinkable with the polymeric elastomer material.

12. The material of claim 1 , wherein the coupling agent is zirconium IV 2,2 (bis 2-propenolatomethyl)butanolato, tris(diisooctyl)pyrophosphato-O.

13. The material of claim 1 , wherein the coupling agent is titanium IV bis(dioctyl)pyrophosphato-O, oxoethylenediolato, adduct, bis(dioctyl) (hydrogen)phosphite-O.

14. The material of claim 1 , wherein the coupling agent is zirconium IV 2,2-bis(2-propenolatomethyl)butanolato, cyclo di[2,2-(bis 2-propenolatomethyl)butanolato], pyrophosphato-O,O.

15. The material of claim 1 , further comprising a phenolic antioxidant.

16. The material of claim 1 , wherein the wax comprises a polymer wax selected from polyethylene waxes, polypropylene waxes, and copolymers thereof.

17. The material of claim 16 , wherein the wax comprises a polyethylene homopolymer.

18. The material of claim 1 , further comprising an amine resin that is crosslinkable with the polymeric elastomer material.

19. The material of claim 18 , wherein the amine resin and the polymeric elastomer material are crosslinked at 10% of sites available for crosslinking to produce a liquid-like soft gel.

20. The material of claim 18 , wherein the amine resin and the polymeric elastomer material are crosslinked at 40-60% of sites available for crosslinking to produce a solid-like soft gel.

21. The material of claim 18 , wherein the material comprises:
from about 5 wt. % to about 10 wt. % of the polymeric elastomer material;
from about 1 wt. % to about 5 wt. % of the wax;
from about 85 wt. % to about 92 wt. % of the thermally conductive filler;
from about 0.5 wt. % to about 1 wt. % of the coupling agent;
from about 0.07 wt. % to about 1.1 wt. % of a phenolic antioxidant; and
less than about 1 wt. % of the amine resin.

22. The material of claim 18 , wherein the amine resin is an alkylated melamine.

23. The material of claim 1 , wherein the polymer elastomer material comprises a material selected from the group consisting of: an ethylene-propylene rubber, a polyethylene/butylene, a polyethylene-butylene-styrene, a polyethylene-propylene-styrene, a hydrogenated polyalkyldiene mono-ol, a hydrogenated polyalkyldiene diol, a hydrogenated polyisoprene, polyolefin elastomer, and blends thereof.

24. The material of claim 1 , wherein the polymer elastomer material comprises a hydrogenated polybutadiene mono-ol.

Assignees

• Merrill Natalie
• Delano Andrew
• Steele David
• Honeywell Int Inc

Inventors

• Merrill Natalie
• Delano Andrew
• Steele David

Classifications

• H10W40/251

  Organics · CPC title

• H10W40/25

  characterised by their materials · CPC title

• H10W40/22

  characterised by their shape, e.g. having conical or cylindrical projections · CPC title

• H01L2924/0002

  Electricity · mapped topic

• H01L2924/3011

  Electricity · mapped topic