Core-Shell LDS Additives for Thermally Conductive Polymer Compositions
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Solution Overview
Problem
There is a need for thermally conductive polymer compositions that provide superior heat dissipation, strength, and flow while retaining the properties required for laser direct structuring in portable electronic devices, which face challenges due to increased heat retention from reduced dimensions.
Innovation Solution
A thermally conductive polymer composition comprising 20-80 wt% polymer component, 0-70 wt% thermally conductive filler, and 0.1-40 wt% laser activatable additive with a core-shell structure, where the core is an inorganic filler and the shell is a laser activatable component, achieving a through-plane thermal conductivity of at least 0.40 W/m K.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermally conductive filler is added to polymer composition, then thermal conductivity is improved, but laser direct structuring capability deteriorates
Solution Approach 1:
The laser activatable additive is segmented into a core-shell structure where the core contains inorganic filler particles and the shell contains laser activatable metal compounds. This segmentation allows the inorganic filler to provide thermal conductivity while the metal compound shell preserves laser direct structuring capability, resolving the contradiction between thermal conductivity improvement and laser processing capability maintenance.
Solution Approach 2:
The invention uses composite materials by combining inorganic filler core with metal compound shell to create a core-shell structured additive. This composite structure integrates the thermal conductivity benefits of inorganic fillers with the laser activatable properties of metal compounds, enabling simultaneous achievement of improved thermal conductivity and maintained laser direct structuring capability.
2Reliability
If laser activatable additive is added to polymer composition, then laser direct structuring capability is improved, but thermal conductivity deteriorates
Solution Approach 1:
The laser activatable additive is segmented into a core-shell structure where the core contains inorganic filler particles and the shell contains laser activatable metal compounds. This segmentation allows the inorganic filler to provide thermal conductivity while the metal compound shell preserves laser direct structuring capability, resolving the contradiction between thermal conductivity improvement and laser processing capability maintenance.
Solution Approach 2:
The invention uses composite materials by combining inorganic filler core with metal compound shell to create a core-shell structured additive. This composite structure integrates the thermal conductivity benefits of inorganic fillers with the laser activatable properties of metal compounds, enabling simultaneous achievement of improved thermal conductivity and maintained laser direct structuring capability.
3Temperature
If thermally conductive filler is added to polymer composition, then heat dissipation is improved, but mechanical strength deteriorates
Solution Approach 1:
The core-shell structured additive combines inorganic filler core with metal compound shell, creating a composite material that provides thermal conductivity while the shell structure helps maintain mechanical integrity. This composite approach allows heat dissipation improvement while minimizing the negative impact on mechanical strength that typically occurs with filler addition.
Solution Approach 2:
The invention changes the parameter of the additive structure from conventional single-phase particles to core-shell structured particles. This structural parameter change allows the inorganic filler core to provide thermal conductivity while the metal compound shell maintains better interfacial bonding with the polymer matrix, thereby preserving mechanical strength while achieving improved heat dissipation.
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 composition effectively enhances thermal conductivity while maintaining mechanical properties and enabling laser direct structuring, suitable for applications in portable electronics.
Implementation Method 1
thermally conductive filler... through plane thermal conductivity of at least about 0.40 W/m K
Implementation Method 2
laser activatable additive... laser direct structuring activation
Data Source
AI summary
The disclosure concerns thermally conductive polymer compositions comprising: (a) from about 20 wt% to about 80 wt% of at least one polymer component; (b) from greater than about 0 wt% to about 70 wt% of a thermally conductive filler; and (c) from about 0.1 wt% to about 40 wt% of a laser activatable additive having a core-shell structure; wherein the core comprises an inorganic filler and the shell comprises a laser activatable component; wherein the combined weight percent value of all components does not exceed about 100 wt%; wherein all weight percent values are based on the total weight of the composition; and wherein a molded sample of the blended thermoplastic composition has a through plane thermal conductivity of at least about 0.40 W/m·K when determined in accordance with ASTM E1461.