Thermally Conductive Grease Composition With Low Siloxane Emissions
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Solution Overview
Problem
Conventional thermally conductive silicone greases cause electrical contact failure due to low molecular siloxane generation, have low drop resistance, and high specific gravity.
Innovation Solution
A non-curable thermally conductive grease composition comprising an ethylene-α-olefin copolymer as a matrix resin, combined with irregularly-shaped alumina, plate-shaped boron nitride, and aggregated boron nitride particles, which are surface-treated with alkoxysilane compounds, to enhance thermal conductivity and reduce specific gravity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thermally conductive silicone grease is used, then thermal conductivity is achieved, but low molecular siloxane is generated causing electrical contact failure
Solution Approach 1:
The patent changes the chemical composition parameters by using ethylene-α-olefin copolymer instead of conventional silicone grease base, and carefully controls the particle size distribution and ratios of thermally conductive fillers (alumina, boron nitride) to prevent low molecular siloxane generation while maintaining thermal conductivity
Solution Approach 2:
The patent creates a composite material system combining ethylene-α-olefin copolymer with a specific mixture of irregularly-shaped alumina, plate-shaped boron nitride, and aggregated boron nitride in controlled ratios, achieving both thermal conductivity and electrical contact reliability without harmful byproducts
2Reliability
If conventional thermally conductive grease is used, then thermal conduction is achieved, but drop resistance is low
Solution Approach 1:
The patent optimizes the viscosity parameter of the ethylene-α-olefin copolymer (10000 mm²/s or less at 40°C) and controls the particle size distribution of fillers to achieve optimal balance between drop resistance and adhesion strength, preventing grease from dripping while maintaining bonding capability
3Reliability
If conventional thermally conductive grease is used, then thermal conductivity is achieved, but specific gravity is high
Solution Approach 1:
The patent changes the material composition by using ethylene-α-olefin copolymer which has lower density than conventional silicone grease, and optimizes the ratio and particle size of thermally conductive fillers to achieve high thermal conductivity with reduced specific gravity
Solution Approach 2:
The patent develops a composite formulation combining lightweight ethylene-α-olefin copolymer matrix with strategically selected thermally conductive particles (alumina and boron nitride) in specific ratios, achieving low specific gravity while maintaining effective thermal conduction
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 minimizes low molecular siloxane generation, exhibits high drop resistance, and maintains a low specific gravity, ensuring effective thermal conductivity and improved workability.
Implementation Method 1
A non-curable thermally conductive grease composition and includes: A. 100 parts by mass of an ethylene-α-olefin copolymer with a kinematic viscosity of 10000 mm2/s or less at 40° C.
Implementation Method 2
B1. 55 to 350 parts by mass of irregularly-shaped alumina with a median particle size of 0.1 to 1 μm, in which a part or all of the alumina is surface treated with an alkoxysilane compound expressed by RaSi(OR′)4-a
Implementation Method 3
B2. 5 to 60 parts by mass of plate-shaped boron nitride with a median particle size of 0.1 to 10 μm; and B3. 55 to 170 parts by mass of aggregated boron nitride with a median particle size of 20 to 70 μm
Data Source
AI summary
A non-curable thermally conductive grease composition includes: A. 100 parts by mass of an ethylene-α-olefin copolymer with a kinematic viscosity of 10000 mm2/s or less at 40° C.; and B. 115 to 580 parts by mass of thermally conductive particles with respect to 100 parts by mass of the component A. The thermally conductive particles contain the following: B1. 55 to 350 parts by mass of irregularly-shaped alumina with a median particle size of 0.1 to 1 μm, in which a part or all of the alumina is surface treated with a specific alkoxysilane compound or its partial hydrolysate; B2. 5 to 60 parts by mass of plate-shaped boron nitride with a median particle size of 0.1 to 10 μm; and B3. 55 to 170 parts by mass of aggregated boron nitride with a median particle size of 20 to 70 μm. The B3/B2 mass ratio is 2 to 20. Thus, the thermally conductive grease composition is less likely to generate low molecular siloxane and has high drop resistance and a low specific gravity.