Composite sheet, production method thereof and electronic apparatus using the same

Patent metadata

Field	Value
Publication number	US-9937683-B2
Application number	US-201514746365-A
Country	US
Kind code	B2
Filing date	Jun 22, 2015
Priority date	Jul 18, 2014
Publication date	Apr 10, 2018
Grant date	Apr 10, 2018

Abstract

A composite sheet includes a graphite layer, a heat insulation layer including a fiber and a heat insulation material and a fiber layer located between the graphite layer and the heat insulation layer, wherein the fiber layer comprises the fiber. An electronic apparatus includes an electronic component that involves heat generation, a housing and the composite sheet, wherein the composite sheet is placed between the electronic component and the housing.

First claim

What is claimed is:

1. A composite sheet, comprising:
a graphite layer;
a heat insulation layer including a resin-based fiber and a heat insulation material; and
a binding portion connecting with the resin-based fiber and combining the graphite layer and the heat insulation layer directly,
wherein the binding portion and the heat insulating layer comprise the same resin-based fiber, and
a recessed portion filled with the binding portion is provided on a surface of the graphite layer,
wherein the binding portion includes a molten layer,
wherein a portion of the resin-based fiber of the binding portion fills the recessed portion.

2. The composite sheet according to claim 1 , wherein the resin-based fiber and the binding portion are integrated.

3. The composite sheet according to claim 1 , wherein the resin-based fiber is a nonwoven fabric.

4. The composite sheet according to claim 1 , wherein the resin-based fiber has a diameter of 0.1 to 30 μm and a bulk density of 0.5 g/m 3 or less.

5. The composite sheet according to claim 1 , wherein the heat insulation material comprises silica aerogel.

6. The composite sheet according to claim 1 , wherein the graphite layer is obtained by heat-treating film.

7. The composite sheet according to claim 1 , wherein the graphite layer has a thickness of 0.1 mm or less, a heat conductivity in a surface direction of 1,000 W/m·K or more, and a heat conductivity in a thickness direction of 20 W/m·K or less; and the heat insulation layer has a thickness within a range of 0.05 mm to 1 mm, and a heat conductivity within a range of 0.01 to 0.1 W/m·K.

8. The composite sheet according to claim 1 , further comprising:
a second graphite layer that is located on a surface of the heat insulation layer, the surface being opposite to the surface on which the graphite layer is located; and
a second binding portion located between the second graphite layer and the heat insulation layer, wherein the second binding portion comprises the resin-based fiber.

9. The composite sheet according to claim 1 , further comprising insulation films on both surfaces of the composite sheet.

10. An electronic apparatus, comprising:
an electronic component that generates heat;
a housing; and
the composite sheet according to claim 1 , wherein the composite sheet is placed between the electronic component and the housing.

11. The composite sheet according to claim 1 , wherein the partly melted fiber is the resin-based fiber heated to a temperature lower than a temperature where melting occurs.

12. The composite sheet according to claim 1 , wherein the partly melted fiber is a portion of the resin-based fiber that has not become completely molten.

13. The composite sheet according to claim 1 , wherein the partly melted fiber is linked to the resin-based fiber in the heat insulation layer.

14. The composite sheet according to claim 1 , wherein the portion of the resin-based fiber of the binding portion which fills the recessed portion is a tip portion of the resin-based fiber.

15. The composite sheet according to claim 1 , wherein the portion of the resin-based fiber of the binding portion which fills the recessed portion is a curve portion of the resin-based fiber.

16. The composite sheet according to claim 1 , wherein the binding portion exists in chunks between the graphite layer and the heat insulation layer.

17. A method of producing a composite sheet, the composite sheet comprising:
a graphite layer;
a heat insulation layer including a resin-based fiber and a heat insulation material; and
a binding portion connecting with the resin-based fiber and combining the graphite layer and the heat insulation layer directly,
wherein the binding portion and the heat insulating layer comprise the same resin-based fiber, and
a recessed portion filled with the binding portion is provided on a surface of the graphite layer,
wherein the binding portion includes a molten layer,
wherein a portion of the resin-based fiber of the binding portion fills the recessed portion, the method comprising:
overlapping the graphite layer and the heat insulation layer;
then heating a side of the graphite layer to melt the fiber in the heat insulation layer that is present in a boundary face between the graphite layer and the heat insulation layer; and
cooling the fiber to laminate the graphite layer and the heat insulation layer.

Assignees

• Panasonic Ip Man Co Ltd

Inventors

• Oikawa Kazuma
• Toyota Kei
• Kohmyohji Daido
• Sakatani Shigeaki

Classifications

• H10W40/10

  Arrangements for heating · CPC title

• H10W40/25

  characterised by their materials · CPC title

• B32B7/04

  Interconnection of layers · CPC title

• B29C66/7444

  Carbon · CPC title

• B32B2266/0228

  Aromatic vinyl resin, e.g. styrenic (co)polymers · CPC title