Heat Conductive Sheet with Catalyst Diffusion Curing
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Solution Overview
Problem
Conventional addition reaction-type heat conductive silicone sheets face challenges in following uneven surfaces of heat generating and dissipating parts, have limited shelf life, and require mixing and defoaming, which complicates handling and can lead to pump-out issues over time.
Innovation Solution
A heat conductive sheet containing a curing catalyst is used, where an uncured composition without a curing catalyst is applied to the sheet's surface, allowing it to cure post-mounting, enabling flexible application and automatic mounting with improved surface adhesion and reduced handling complexities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional addition reaction-type heat conductive silicone sheets are used, then heat conductivity is improved, but the sheets cannot easily follow the unevenness of heat generating and dissipating parts
Solution Approach 1:
The patent changes the physical state parameter of the heat conductive material from cured (rigid) to uncured (viscous) form, allowing it to flow and conform to uneven surfaces. The material maintains its heat conductive properties while gaining the ability to follow surface irregularities during the uncured state before mounting.
2Ease of operation
If liquid silicone rubbers are used to follow unevenness, then the ability to conform to surfaces is improved, but mixing and defoaming are necessary which complicates handling
Solution Approach 1:
The patent segments the heat conductive material into two separate components: a cured sheet containing the curing catalyst and an uncured composition. This segmentation eliminates the need for mixing before use, as the uncured composition is already in its final form and can be directly applied to the sheet without additional preparation steps.
Solution Approach 2:
The curing catalyst is pre-loaded into the cured sheet during manufacturing, so that when the uncured composition is applied, curing can begin immediately without requiring any preliminary mixing or preparation. The sheet is prepared in advance with the catalyst embedded, enabling direct application and subsequent curing.
3Ease of operation
If grease is used to follow unevenness, then conformability is improved, but pump-out occurs leading to malfunction over time
Solution Approach 1:
The patent changes the chemical state of the heat conductive material from non-curing (grease) to curing (cross-linking) form. The uncured composition cures in place after application, transforming from a potentially mobile grease-like substance into a stable, cross-linked gel or rubber that maintains its position and prevents pump-out, ensuring long-term reliability.
Solution Approach 2:
The patent creates a composite structure combining the cured sheet (providing structural support and heat conductivity) with the uncured composition (providing conformability and adhesion). This composite material system achieves both the flexibility needed to follow uneven surfaces and the stability required to prevent pump-out over time.
4Temperature
If conventional heat conductive sheets are used, then heat conductivity is provided, but automatic mounting is difficult due to handling requirements
Solution Approach 1:
The patent segments the heat conductive material into a pre-prepared cured sheet with catalyst and a separate uncured composition, eliminating mixing requirements. This segmentation enables automatic dispensing systems to apply the uncured composition directly to the sheet without human intervention for mixing, facilitating automatic mounting processes.
Solution Approach 2:
The cured sheet performs the self-service function of containing the curing catalyst, automatically initiating the curing process of the applied uncured composition without requiring external mixing or preparation. This self-contained system simplifies automation by eliminating manual intervention steps.
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 allows for easy adherence to uneven surfaces, automatic mounting, and reliable curing of the uncured composition, enhancing heat conductivity and reducing production costs while preventing pump-out issues.
Implementation Method 1
curing the heat conductive uncured composition by diffusion of the curing reaction catalyst contained in the heat conductive sheet
Implementation Method 2
a heat conductive sheet containing a curing reaction catalyst, in which a heat conductive uncured composition not containing a curing reaction catalyst is joined or applied to the heat conductive sheet containing a curing reaction catalyst so as to be cured by the curing reaction catalyst
Data Source
AI summary
A heat conductive sheet of the present invention is a heat conductive sheet containing a curing reaction catalyst, wherein a heat conductive uncured composition 2 not containing a curing reaction catalyst is joined to at least one principal surface of the heat conductive sheet 1 containing a curing reaction catalyst. The heat conductive sheet 1 containing a curing reaction catalyst contains the curing reaction catalyst in an amount necessary to cure the heat conductive uncured composition. A mounting method of the present invention includes: joining a heat conductive uncured composition 2 not containing a curing reaction catalyst to at least one principal surface of the heat conductive sheet 1 containing a curing reaction catalyst, and curing the heat conductive uncured composition by diffusion of the curing reaction catalyst contained in the heat conductive sheet 1. Thereby, the heat conductive uncured composition can be joined to the heat conductive sheet immediately before mounting to an electronic component or the like, easily follow the unevenness of a heat generating part and/or heat dissipating part, and cure after mounting.