Multilayer Resin Sheet Adhesion and Thermal Conductivity
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Solution Overview
Problem
Existing thermally conductive resin compositions face challenges in achieving high thermal conductivity, adhesion strength, and insulating properties simultaneously, particularly with boron nitride fillers which exhibit low adhesion strength and difficulty in controlling resin flowability due to their scale-like shape and non-Newtonian fluid behavior.
Innovation Solution
A multilayer resin sheet is developed with a resin composition layer containing a thermosetting resin and a boron nitride filler, accompanied by an adhesive layer with specific surface roughness and thickness, enhancing adhesion and thermal conductivity by embedding the filler in the adhesive layer and optimizing the resin composition's filler content and particle size distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If boron nitride filler is used to achieve high thermal conductivity, then thermal conductivity is improved, but adhesion strength deteriorates due to the soft nature of boron nitride
Solution Approach 1:
The invention uses a composite system consisting of boron nitride filler (for thermal conductivity) combined with specific thermosetting resins (epoxy resin, amine curing agent, and curing catalyst) to create a resin composition that achieves both high thermal conductivity and adequate adhesion strength. The composite structure allows the boron nitride particles to provide thermal pathways while the resin matrix provides binding and adhesion.
2Temperature
If boron nitride filler with scale-like shape is used to improve thermal conductivity, then thermal conductivity is improved, but resin flowability control deteriorates due to non-Newtonian fluid behavior
Solution Approach 1:
The invention controls resin flowability by carefully adjusting the parameters of the resin composition system, including the types and amounts of epoxy resin, amine curing agent, and curing catalyst. By optimizing these compositional parameters, the patent achieves manageable viscosity and flow characteristics despite the presence of scale-like boron nitride particles that induce non-Newtonian behavior.
3Temperature
If high filler content is used to achieve high thermal conductivity, then thermal conductivity is improved, but insulating properties deteriorate
Solution Approach 1:
The invention optimizes the filler content parameter within a specific range (40-85% by volume) to balance thermal conductivity and insulating properties. This parameter optimization ensures that sufficient boron nitride is present for thermal management while maintaining enough resin matrix to provide electrical insulation and prevent direct conductive pathways for electricity.
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 multilayer resin sheet achieves excellent thermal conductivity, adhesion strength, and insulating properties, improving dielectric breakdown strength and reducing the risk of exfoliation under thermal shock, while maintaining thermal conductivity post-curing.
Implementation Method 1
an adhesive layer that is disposed on at least one surface of the resin composition layer, the adhesive layer having an arithmetic average surface roughness Ra of 1.5 μm or less at a surface that does not face the resin composition layer
Implementation Method 2
a resin composition layer that comprises a thermosetting resin and a filler... the filler comprises a boron nitride filler... achieve a thermal conductivity of from 6 to 11 W/mK as measured by temperature wave analysis
Implementation Method 3
a cured multilayer resin sheet and a method for producing the same... a resin composition layer that comprises a thermosetting resin... a cured product of a composite system of a typical bisphenol A epoxy resin and an alumina filler
Implementation Method 4
improving dielectric breakdown strength and reducing the risk of exfoliation under thermal shock
Data Source
Figure 1~2
Figure 3(a)~3(c)
Figure 4(a)~5(b)
AI summary
The invention provides a multilayer resin sheet that includes: a resin composition layer that includes a thermosetting resin and a filler; and an adhesive layer that is disposed on at least one surface of the resin composition layer, the adhesive layer having an arithmetic average surface roughness Ra of 1.5 µm or less at a surface that does not face the resin composition layer.