Oriented hBN Polymer Composite for High Thermal Conductivity

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Solution Overview

Problem

There is a need to enhance the variety and efficiency of materials suitable for thermal management in industries such as consumer electronics, telecommunication infrastructure, LED lighting, hybrid and electric vehicles, and solar cells, where thermally conductive polymer composites can significantly lower operating temperatures and prolong device life by dissipating heat.

Innovation Solution

A composite body comprising an organic polymer and hexagonal boron nitride (hBN) particles distributed throughout with a high degree of orientation, achieved through mechanical exfoliation, surface functionalization, and alignment under pressure, resulting in a thermal conductivity of at least 10 W/mK with hBN concentrations below 40 vol %.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If hBN concentration is increased to improve thermal conductivity, then thermal conductivity increases, but material cost and processing difficulty increase

Engineering Contradiction:

Improvethermal conductivityVSAvoidhBN concentration

Core Design Contradiction:

TemperatureVSQuantity of substance

Solution Approach 1:

The patent uses hexagonal boron nitride (hBN) particles dispersed in a polymer matrix to create a composite material with enhanced thermal conductivity. The composite structure allows achieving high thermal performance (≥10 W/mK) with optimized hBN concentration (20-40 vol%) rather than using pure hBN or higher concentrations, resolving the contradiction between thermal conductivity improvement and material quantity/cost.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies surface functionalization to hBN particles to improve their interfacial thermal conductivity with the polymer matrix. By modifying the local quality at the particle-matrix interface, the composite achieves higher overall thermal conductivity with lower hBN concentration, as the functionalized surface enhances heat transfer efficiency without requiring increased filler content.

Inventive Principle:

Principle #3Local quality

2Temperature

If hBN particles are added to polymer matrix, then thermal conductivity improves, but electrical insulation performance may deteriorate

Engineering Contradiction:

Improvethermal conductivityVSAvoidelectrical insulation

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent applies surface functionalization to hBN particles to modify their local properties at the interface with the polymer matrix. This local modification enhances thermal conductivity at the interface while maintaining the electrical insulation properties of the bulk polymer matrix, thus resolving the contradiction between thermal conductivity improvement and electrical insulation preservation.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The composite structure with optimized hBN concentration (20-40 vol%) and surface functionalization creates a material that achieves high thermal conductivity while maintaining the polymer matrix's electrical insulation properties. The composite design allows simultaneous optimization of thermal and electrical properties.

Inventive Principle:

Principle #40Composite materials

3Temperature

If hBN particles are dispersed in polymer, then thermal management efficiency improves, but processing complexity increases

Engineering Contradiction:

Improvethermal conductivityVSAvoidprocessing complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent applies surface functionalization to hBN particles before dispersion into the polymer matrix. This preliminary action modifies the particle surface to improve compatibility and dispersion uniformity, reducing processing difficulties and complexity during subsequent composite fabrication steps while achieving the desired thermal conductivity.

Inventive Principle:

Principle #10Preliminary action

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 composite body achieves high thermal conductivity, maintaining efficiency with lower hBN concentrations, thereby optimizing thermal management in various industries.

Implementation Method 1

a composite body including an organic polymer and ceramic particles comprising hexagonal boron nitride (hBN) particles distributed throughout the organic polymer... the composite body achieves high thermal conductivity

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12584056B2Composite body having high thermal conductivity and method of making the composite body

Publication Date: 2026.03.24 SAINT GOBAIN CERAMICS & PLASTICS INC

AI summary

A composite article can comprise a composite body including an organic polymer and ceramic particles comprising hexagonal boron nitride (hBN) particles distributed throughout the organic polymer, wherein an amount of the hBN particles ranges from 20 vol % to 40 vol % based on a total volume of the body; and the body comprises an in plane thermal conductivity of at least 10 W/mK. The hBN particles within the composite body can have a March-Dollase Orientation parameter η of at least 50%.