Thermally Conductive Elastomer Composition With Low Oil Bleeding
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Solution Overview
Problem
Known thermally conductive molded articles face issues with reworkability and oil bleeding resistance, as they tend to adhere to each other and exhibit significant oil leakage.
Innovation Solution
A thermally conductive elastomer composition comprising a styrene-based elastomer, petroleum-based hydrocarbon process oil with a weight average molecular weight of not greater than 600, a nonionic surfactant with an HLB value of 2.0 or greater, aluminum hydroxide powder, and artificial graphite powder, which enhances reworkability and oil bleeding resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thermally conductive molded article is made with conventional composition, then thermal conductivity is improved, but reworkability deteriorates (adhesion between overlapped articles)
Solution Approach 1:
The invention changes the molecular weight parameter of the process oil to not greater than 600 and adjusts the HLB value parameter of the nonionic surfactant to 2.0 or greater. These parameter changes optimize the balance between thermal conductivity and reworkability, allowing the molded article to maintain good thermal conduction while preventing excessive adhesion that would hinder reworkability.
Solution Approach 2:
The invention uses a composite material system comprising styrene-based elastomer, process oil with specific molecular weight, nonionic surfactant with specific HLB value, aluminum hydroxide powder, and artificial graphite powder. This composite formulation achieves both good thermal conductivity through the graphite and aluminum hydroxide fillers, and appropriate reworkability through the optimized process oil and surfactant combination.
2Temperature
If a thermally conductive molded article is made with conventional composition, then thermal conductivity is improved, but oil bleeding resistance deteriorates (oil oozing to outside)
Solution Approach 1:
The invention changes the molecular weight parameter of the process oil to not greater than 600, which optimizes the oil's viscosity and compatibility with the elastomer matrix. This parameter change reduces oil bleeding while maintaining thermal conductivity. Additionally, the nonionic surfactant with HLB value of 2.0 or greater is introduced to improve oil compatibility and prevent oil separation.
Solution Approach 2:
The nonionic surfactant acts as an intermediary substance between the process oil and the styrene-based elastomer matrix. With an HLB value of 2.0 or greater, it improves the compatibility and dispersion of the process oil in the elastomer, preventing oil bleeding to the outside while maintaining the thermal conductivity provided by the fillers.
3Ease of operation
If process oil with low molecular weight is used, then reworkability is improved, but oil bleeding increases
Solution Approach 1:
The nonionic surfactant with HLB value of 2.0 or greater serves as a mediator between the low molecular weight process oil and the elastomer matrix. It compensates for the potential oil bleeding issue caused by low molecular weight oil by improving compatibility and preventing oil separation, while allowing the low molecular weight oil to provide good reworkability.
Solution Approach 2:
The invention uses a composite system where process oil with molecular weight not greater than 600 is combined with nonionic surfactant having HLB value of 2.0 or greater. This composite approach allows the low molecular weight oil to provide good reworkability while the surfactant prevents oil bleeding, resolving the contradiction between these two properties.
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 provides excellent reworkability, reduced oil bleeding, and improved thermal conductivity, insulating properties, while maintaining low hardness and moldability, allowing for effective heat dissipation without adhering to surfaces.
Implementation Method 1
a thermally conductive elastomer composition containing: 100 parts by mass of a styrene-based elastomer; from 610 to 750 parts by mass of a process oil formed of a petroleum-based hydrocarbon, the process oil having a weight average molecular weight of not greater than 600; from 25 to 40 parts by mass of a solid nonionic surfactant having an HLB value of 2.0 or greater; from 260 to 640 parts by mass of aluminum hydroxide powder; and from 250 to 340 parts by mass of artificial graphite powder
Data Source
AI summary
A thermally conductive elastomer composition of the present invention contains: 100 parts by mass of a styrene-based elastomer; from 610 to 750 parts by mass of a process oil formed of a petroleum-based hydrocarbon, the a process oil having a weight average molecular weight of not greater than 600; from 25 to 40 parts by mass of a solid nonionic surfactant having an HLB value of 2.0 or greater; from 260 to 640 parts by mass of aluminum hydroxide powder; and from 250 to 340 parts by mass of artificial graphite powder.