Low VOC Thermal Interface Material Using Block Copolymer Resin
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Solution Overview
Problem
Current thermal interface materials face challenges in achieving high thermal conductivity, mechanical performance, conformability, and low volatile organic compound (VOC) content while maintaining dimensional stability and handling efficiency, particularly in large-area applications like automotive batteries.
Innovation Solution
A thermal interface material comprising thermally conductive fillers dispersed in a resin system based on block copolymers, with specific formulations including styrene-isoprene-styrene block copolymers and hexagonal boron nitride, combined with tackifiers and plasticizers, to achieve low VOC content and enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermally conductive fillers are dispersed in conventional resin systems to improve thermal conductivity, then thermal conductivity is improved, but volatile organic compound content increases
Solution Approach 1:
The patent changes the chemical composition parameters of the resin system by using block copolymers with specific glass transition temperatures and controlled architectures (star, linear, branched) to achieve low VOC content while maintaining thermal conductivity enhancement through filler dispersion
Solution Approach 2:
The patent creates a composite material system combining thermally conductive fillers (such as aluminum oxide, aluminum nitride, boron nitride) with specially formulated block copolymer resin systems, where the composite achieves both high thermal conductivity and low VOC content through synergistic material selection
2Object-generated harmful factors
If resin system composition is optimized for low VOC content, then VOC content is reduced, but mechanical performance and handling efficiency deteriorate
Solution Approach 1:
The patent optimizes multiple parameters of the block copolymer system including glass transition temperature ranges, molecular weight, and architectural structure (star, linear, branched) to achieve the optimal balance between low VOC content and maintained mechanical performance
Solution Approach 2:
The patent applies different block copolymer components with specific properties to different functional requirements within the resin system, creating localized optimization where certain blocks provide structural integrity while others ensure low VOC and good filler compatibility
3Object-generated harmful factors
If material formulation is simplified to reduce VOC content, then VOC content is reduced, but conformability and dimensional stability worsen
Solution Approach 1:
The patent formulates a multi-component composite resin system comprising different block copolymer types (star, linear, branched) with complementary properties that collectively provide conformability, dimensional stability, and low VOC content, where each component contributes specific functional qualities
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides improved thermal conductivity, mechanical stability, and reduced VOC emissions, while maintaining conformability and dimensional stability, effectively addressing the conflicting requirements of thermal and mechanical performance in large-area applications.
Implementation Method 1
the thermally conductive filler comprises hexagonal boron nitride
Implementation Method 2
The resin system comprises a block copolymer and has a Volatile Organic Compound content of no greater than 500 ppm
Implementation Method 3
The resin system further comprises at least one tackifier
Implementation Method 4
the resin system further comprises at least one plasticizer
Data Source
Figure 1
AI summary
Low Volatile Organic Content (VOC) thermal interface materials are described. The thermal interface materials include heat conducting fillers such a hexagonal boron nitride dispersed in a block copolymer resin system. Depending on the requirements, tackifiers and plasticizers may be included in the resin system while still retaining low VOC levels.