Resin Composition Thermal Conductivity Anisotropy Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional resin compositions struggle to achieve high levels of both thermal conductivity and insulating properties while maintaining a low relative density and avoiding anisotropy in thermal conductivity, especially during processing under shear like injection molding.
Innovation Solution
A resin composition comprising a carbon-based nanofiller, a modified polyolefin-based polymer, and two or more resins, where the modified polyolefin-based polymer forms a phase structure with the carbon-based nanofiller in a dispersed phase and other resins in a continuous phase, with the polymer present at the interface to enhance thermal conductivity and insulating properties and prevent anisotropy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If carbon-based nanofiller is dispersed in a single resin phase to form thermally conductive path, then thermal conductive properties are improved, but electrical conductive properties are enhanced as well making it inapplicable where insulating properties are required
Solution Approach 1:
The resin composition is segmented into two distinct resin phases (first resin phase and second resin phase) with different affinities for the carbon-based nanofiller. The carbon-based nanofiller is selectively dispersed in the first resin phase while the second resin phase remains substantially free of the nanofiller, creating isolated conductive regions that prevent electrical short circuits while maintaining thermal conductivity
Solution Approach 2:
The carbon-based nanofiller is locally concentrated in the first resin phase which has high affinity for it, creating localized thermally conductive regions. The second resin phase with low affinity for the nanofiller acts as an insulating matrix, providing local electrical insulation while the overall composition maintains thermal conductive properties through the distributed first resin phase regions
2Object-generated harmful factors
If electrically insulating material such as alumina is dispersed in commodity resin to reduce electrical conductive properties, then insulating properties are improved, but relative density increases and formability deteriorates
Solution Approach 1:
The invention changes the approach from adding heavy inorganic insulating materials to utilizing the inherent insulating properties of the second resin phase and the controlled distribution of carbon-based nanofiller. This parameter change in the composition strategy achieves electrical insulation without the density penalty of alumina or other heavy fillers
Solution Approach 2:
The invention creates a composite resin system with two different resin phases that work together to provide both electrical insulation and thermal conductivity. The first resin phase contains the carbon-based nanofiller for thermal conduction while the second resin phase provides electrical insulation, eliminating the need for additional heavy inorganic fillers
3Temperature
If carbon-based nanofiller is added to improve thermal conductive properties, then thermal conductivity is enhanced, but anisotropy of thermal conductivity occurs when subjected to shear processing
Solution Approach 1:
The resin composition is segmented into multiple resin phases that distribute the carbon-based nanofiller throughout the matrix. This segmentation prevents the nanofiller from aligning in a single direction during shear processing, as the nanofiller is confined within and distributed across multiple resin phase regions, thereby reducing anisotropy in thermal conductivity
Solution Approach 2:
The carbon-based nanofiller is locally dispersed in the first resin phase regions rather than being uniformly distributed throughout a single continuous matrix. This local quality approach creates multiple isolated conductive pathways that are less susceptible to directional alignment under shear stress, maintaining more isotropic thermal conductivity
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 resin composition achieves high thermal conductivity and insulating properties with reduced relative density and anisotropy, even under shear processing, by localizing the carbon-based nanofiller and modifying the polymer's role at the interface.
Implementation Method 1
carbon-based nanofillers are excellent in thermal conductive properties, electrical conductive properties, mechanical properties and the like
Implementation Method 2
a phase structure as shown in FIG. 1 is formed of a dispersed phase containing the carbon-based nanofiller and a continuous phase
Data Source
AI summary
A resin composition comprises a carbon-based nanofiller (A), a modified polyolefin-based polymer (B), and two or more resins (C) other than the modified polyolefin-based polymer (B), the resin composition comprising a dispersed phase formed from a resin (Caff) which has a highest affinity for the carbon-based nanofiller (A) among the two or more resins (C), and a continuous phase formed from the remaining one or more resins (C1), wherein at least part of the modified polyolefin-based polymer (B) is present at an interface between the dispersed phase and the continuous phase, and the carbon-based nanofiller (A) is present in the dispersed phase.