Boron Nitride Resin Composite for Thermal Management
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Solution Overview
Problem
The increasing integration density of electronic components demands composite bodies with excellent insulation properties for efficient heat dissipation, which existing methods have not adequately addressed.
Innovation Solution
A manufacturing method involving a sintering step to create a boron nitride sintered body with pores, followed by impregnation with a resin composition, reducing voids and enhancing electrical insulation properties, suitable for use as a heat dissipation member or in other applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a porous ceramic molded body is impregnated with resin to improve insulation properties, then electrical insulation properties are improved, but voids remain in the composite body
Solution Approach 1:
The patent utilizes a porous ceramic molded body as the base structure for impregnation. The porous structure allows resin to penetrate and fill the pores, improving electrical insulation properties while maintaining the heat dissipation characteristics of the ceramic material.
Solution Approach 2:
The patent changes the physical and chemical parameters of the resin composition (viscosity, molecular weight, functional groups) to optimize impregnation effectiveness. By adjusting these parameters, the resin can properly penetrate the porous structure and fill voids, achieving both good insulation and minimal voids.
2Productivity
If resin composition with low viscosity is used for impregnation, then impregnation efficiency is improved, but resin strength is reduced
Solution Approach 1:
The patent optimizes resin composition parameters including viscosity, molecular weight, and functional groups. This balanced approach allows the resin to have low enough viscosity for efficient impregnation while maintaining sufficient strength through proper molecular structure and crosslinking mechanisms.
Solution Approach 2:
The patent creates a composite structure where resin impregnates the porous ceramic body. The combination of ceramic and resin materials provides both the impregnation efficiency needed for production and the structural strength required for the final composite body, with each material compensating for the other's weaknesses.
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 method produces composite bodies with improved electrical insulation and thermal conductivity, suitable for electronic components, reducing size and weight while maintaining high strength and reliability.
Implementation Method 1
The pore diameter of the pores included in this boron nitride sintered body is sufficiently small. In the impregnating step, the pores can be sufficiently impregnated with the resin composition by capillarity accordingly.
Data Source
Figure 1
AI summary
Provided is a method for manufacturing a composite body, the method including: a nitriding step of firing a boron carbide powder in a nitrogen atmosphere to obtain a fired product containing boron carbonitride; a sintering step of molding and heating a blend containing the fired product and a sintering aid to obtain a boron nitride sintered body including boron nitride particles and pores; and an impregnating step of impregnating the boron nitride sintered body with a resin composition, the composite body having the boron nitride sintered body and a resin filled in at least some of the pores of the boron nitride sintered body.