Specification
THIN BOND-LINE SJL1CONE ADHESIVE
COMPOSITION AND METHOD FOR PREPARING THE SAME
BACKGROUND OF THE INVENTION
The present disclosure relates to the composition and preparation of thermally
conductive composites containing filters with a maximum particle diameter of less
than 25 microns to reduce bond line thickness, decrease in-situ thermal resistance and
improve in-situ heat transfer of thermal interface materials made from such
compositions.
Many electrical components generate heat during periods of operation. As electronic
devices become denser and more highly integrated, the heat flux increases
exponentially. At the same time, because of performance and reliability
considerations, the devices need to operate at lower temperatures, thus reducing the
temperature difference between the heat generating part of the device and the ambient
temperature, which decreases the thermodynamic driving force for heat removal. The
increased heat flux and reduced thermodynamic driving force thus require
increasingly sophisticated thermal management techniques to facilitate heat removal
during periods of operation.
Thermal management techniques often involve the use of some form of heat
dissipating unit (which includes, but is not limited to, heat spreader, heat sink, lid,
heat pipe, or any other designs and constructions known to those skilled in the art) to
conduct heat away from high temperature areas in an electrical system. A heat
dissipating unit is a structure formed from a high thermal conductivity material (e.g.,
copper, aluminum, silicon carbide, metal alloys, polymer composites and ceramic
composites) that is mechanically coupled to a heat generating unit to aid in heat
removal. In a relatively simple form, a dissipating unit can include a piece of metal
(e.g., aluminum or copper) that is in contact with the heat generating unit. Heat from
the heal generating unit flows into the heat dissipating unit through the mechanical
interface between the units.
In a typical electronic package, a heat dissipating unit is mechanically coupled to the
heat producing component during operation by positioning a flat surface of the heat
dissipating unit against a flat surface of the heat generating component and holding
the heat dissipating unit in place using some form of adhesive or fastener. As can be
appreciated, the surface of the heat dissipating unit and the surface of the heat
generating component will rarely be perfectly planar or smooth, so air gaps will
generally exist between the surfaces. As is generally well known, the existence of air
gaps between two opposing surfaces reduces the ability to transfer heat through the
interface between the surfaces. Thus, these air gaps reduce the effectiveness and
value of the heat dissipating unit as a thermal management device. To address this
problem, polymeric compositions have been developed for placement between the
heat transfer surfaces to decrease the thermal resistance therebetween.
In general, a heat dissipating unit is attached to the heat generating component via a
thin-layer of thermal interface material (TIM). This material is typically a filled
polymer system. The effectiveness of heat removal from the device depends on the
in-situ thermal resistance of the TIM material which, in turn, depends not only on the
bulk thermal conductivities of the TIM material, but also the attainable bond line
thickness under industrially relevant pressure and the interfacial resistance. The
minimum thickness of the TIM is determined by the degree of surface planarity and
roughness of both the heat generating and the heat dissipating units, or the maximum
(agglomerated) filler size, whichever is larger. However, this minimum bondline may
not be always attainable, especially with highly viscous and thixotropic formulations,
under industrially relevant pressure, typically below 250 psi, and more typically at or
below 100 psi. In addition, a formulation's viscosity, wettability to the surface, film
forming capability and storage stability can greatly affect interfacial resistance and
thus the thermal interface material's in-device heat transfer capability.
In many TIM applications the TIM must be sufficiently compliant to provide
mechanical isolation of the heat generating component and the heat dissipating unit in
those cases where the Coefficient of Thermal Expansion (CTE) of the heat generating
component is significantly different (higher or lower) than that of the heat dissipating
unit. In such applications, TIM materials have to not only provide an efficient heat
transfer pathway bui also maintain structural integrity for the whole package or
device. They have therefore to maintain satisfactory mechanical as well as thermal
properties throughout the lifetime of the device.
A need therefore exists for improved compositions to effectively transfer heat
between a heat dissipating unit and a heat producing component while maintaining
mechanical integrity throughout the device lifetime.
BRIEF DESCRIPTION OF THE INVENTION
Thermal interface compositions in accordance with this disclosure are polymeric
composites containing filler particles that are 25 microns or Jess in diameter. Thermal
resistance can be minimized with a low viscosity formulation that demonstrates a low
bond line thickness, good wettability to the substrates to be bonded and good film
forming ability. The viscosity of the formulation can be affected by the processing
conditions, which include, but are not limited to, order of addition, mixing speed and
time, temperature, humidity, vacuum level and filler treatment procedures. In
addition, the thermal resistance of the heat generating - heat dissipating system is
minimized due to the smaller particle sizes that address interfacial contact resistances.
Electrical components are also described herein which include a heat producing
component and a heat dissipating unit each in contact with a thermal interface
composition of the present disclosure.
Methods of increasing the efficiency of heat transfer in accordance with this
disclosure include the steps of interposing a thermal interface composition between a
heat producing component and a heat dissipating unit.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a schematic representation of an electrical component in accordance with
this disclosure.
Figure 2 is a schematic representation of a testing sample including compositions in
accordance with this disclosure placed between two coupons, which may be metalmetal,
metal-silicon or silicon-silicon.
Figure 3 is a schematic representation of a die shear setup used to measure adhesion
strength of compositions in accordance with this disclosure.
DETAILED DESCRIPTION OF THE INVENTION
The composition of the present disclosure is a matrix containing filler particles below
25 microns in size. These composites can achieve lower attainable bond line
thickness, which allows a lower attainable in-situ thermal resistance. The
composition of the present disclosure is especially useful as a thermal interface
material between two or more substrates to aid in heat removal from a heat source or a
heat generating device.
The matrix can be any polymeric material. Suitable organic matrices include, but are
not limited to, polydimethylsiloxane resins, epoxy resins, acrylate resins, other
organo-functionalized polysiloxane resins, polyimide resins, fluorocarbon resins,
benzocyclobutene resins, fluorinated polyallyl ethers, polyamide resins,
polyimidoamide resins, phenol resol resins, aromatic polyester resins, polyphenylene
ether (PPE) resins, bismaleimide triazine resins, fluororesins, mixtures thereof and
any other polymeric systems known to those skilled in the art. (For common
polymers, see "Polymer Handbook:, Branduf, J.,; Immergut, E.H; Grulke, Eric A;
Wiley Interscience Publication, New York, 4lh ed.(1999); "Polymer Data Handbook
Mark, James Oxford University Press, New York (1999)). Preferred curable
thermoset matrices are acrylate resins, epoxy resins, polydimethyl siloxane resins,
other organo-functionalized polysiloxane resins that can form cross-linking networks
via free radical polymerization, atom transfer, radical polymerization ring-opening
polymerization, ring-opening metathesis polymerization, anionic polymerization,
cationic polymerization or any other method known to those skilled in the art, and
mixtures thereof. Suitable curable silicone resins include, for example, the addition
curable and condensation curable matrices as described in "Chemistry and
Technology of Silicone", Noll, W.; Academic Press 1968. Where the polymer matrix
is not a curable polymer, the resulting thermal interface composition can be
formulated as a gel, grease or phase change materials that can hold components
together during fabrication and thermal transfer during operation of the device.
In another embodiment, the polymeric matrix can be an organic-inorganic hybrid
matrix. Hybrid matrices include any polymers that contain chemically bound main
group metal elements (e.g., aluminum, magnesium, gallium, indium), main group
semi-metal elements (e.g. boron, germanium, arsenic, antimony), phosphorous,
selenium, transition metal elements (e.g., platinum, palladium, gold, silver, copper,
zinc, zirconium, titanium, ruthenium, lanthanum, etc.) or inorganic clusters (which
include, but are not limited to, polyhedral oligomeric silsesquioxanes, nano metal
oxides, nano silicon oxides, nano metal particles coated with metal oxides, and nano
metal particles.) For typical examples and methods of forming inorganic-organic
hybrids, see reviews such as "Hybrid Organic Inorganic Materials - in Search of
Synergic Activity" by Pedro Gomez-Romero, Advanced Materials, 2001, Vol. 13, No.
3, pp: 163-174; "Inorganic Clusters in Organic Polymers and the Use of
Polyfunctional Inorganic Compounds as Polymerization Initiators" by Guido
Kickelbick and Ulrich Schubert, Monatshefte fur Chemie, 2001, Vol. 132, pp. 13-30;
"Synthesis and Application of Inorganic/Organic Composite Materials", by Helmut
Schmidt, Macromolecular Symposia, 1996, Vol. 101, pp. 333-342; and "Synthesis of
Nanocomposite Organic/Inorganic Hybrid Materials Using Controlled/ 'Living'
Radical Polymerization" by Jeffrey Pyun and Krzysztof Matyjaszewski, Chemistry of
Materials, 2001, Vol. 13. pp. 3436-3448. As used herein, "chemically bound" refers
to bonding through a covalent bond, an ionic interaction, an iono-covalent bond, a
dative bond or a hydrogen bond. Organic-inorganic hybrid polymeric matrices may
refer to, but are not limited to, copolymerization products between organic monomers,
oligomers or polymers that contain polymerizable groups such as alkenyl, ally!, Si-H,
acrylate, methacrylate, styrenic, isocyanate, epoxide and other common groups known
to those skilled in the art, and inorganic clusters or organometallic compounds
containing polymerizable groups. For example, the copolymerization product
between an acrylate or a methacrylate and a metal acrylate or methacrylate compound
is an organic-inorganic hybrid polymeric matrix. The copolymerization product
between an epoxide and an epoxide-functionalized inorganic cluster is also considered
an inorganic-organic hybrid polymer. The homorpolymerizatioh products of organofunctionalized
inorganic clusters or organometallic compounds, or the
copolymerization products among different organo-functionalized inorganic clusters
or organometallic compounds, are also considered organic-inorganic hybrid matrices.
Organic-inorganic hybrid matrices also include cases where the inorganic cluster or
organometallic compound has no polymerizable functional groups, but can become
part of the polymer network through its surface OH or other functional groups.
In a preferred embodiment, the matrix is an addition curable silicone rubber
composition including the following components:
(A) 100 parts by weight of an organopolysiloxane containing an average of at least
two silicon-bonded alkenyl groups per molecule;
(B) 0.1-50 parts by weight of an organohydrogenpolysiloxane containing an average
of at least two silicon-bonded hydrogen atoms per molecule;
(C) a hydrosilylation catalyst;
and optionally
(D) catalyst inhibtor(s); and
(E) adhesion promoters.
Where utilized, the organopolysiloxane (component A) contains an average of at least
two alkenyl groups bonded with silicon atoms per molecule. The alkenyl groups that
are bonded with silicon atoms include, for example, vinyl groups, ally! groups,
butenyl groups, pentenyl groups, hexenyl groups and heptenyl groups. Of these, vinyl
groups are particularly preferred. The bonding positions of the alkenyl groups in the
organopolysiloxane include, for example, the terminals of the molecular chain and/or
side chains of the molecular chain. Organic groups that are bonded with the silicon
atoms in addition to the alkenyl groups of (he organopolysiloxane include, for
example, alkyl groups such as methyl groups, ethyl groups, propyl groups, butyl
groups, pentyl groups, hexyl groups and heptyl groups, aryl groups such as phenyl
groups, tolyl groups, xylyl groups and naphthyl groups, aralkyl groups such as benzyl
groups and phenethyl groups and halogenated groups such as chloromethyl groups, 3-
chloropropyl groups and 3,3,3-trifluoropropyl groups, with methyl groups and phenyl
groups being particularly preferred. The molecular structure of the
organopolysiloxane can be, for example, in straight chain form, a straight chain form
having some branches, in cyclic form and in branched chain form, with the straight
chain form being particularly desirable. Although there is no limitation on the
viscosity of the organopolysiloxane, a viscosity in the range of about 10 to about
500,000 centipoise at 25° C. is preferred, with a range of about 50 to about 5,000
centipoise being particularly preferred.
The organopolysiloxane (component A) can include, for example, copolymers of
dimethyl siloxane blocked with trimethylsiloxy groups at both terminals of the
molecular chain and of methyl vinyl siloxane; methyl vinyl polysiloxane blocked with
trimethylsiloxy groups at both terminals of the molecular chain; copolymers of
dimethyl siloxane blocked with trimethylsiloxy groups at both terminals of the
molecular chain, methyl vinyl siloxane and methyl phenyl siloxane; dimethyl
polysiloxane blocked with dimethyl vinyl siloxane groups at both terminals of the
molecular chain; methyl vinyl polysiloxane blocked with dimethyl vinyl siloxane
groups at both terminals of the molecular chain; copolymers of dimethyl siloxane
blocked with dimethyl vinyl siloxane groups at both terminals of the molecular chain
and of methyl vinyl siloxane; copolymers of dimethyl siloxane blocked with dimethyl
vinyl siloxane groups at both terminals of the molecular chain, methyl vinyl siloxane
and methyl phenyl siloxane; organopolysiloxane copolymers comprised of siloxane
units as indicated by the formula R'jSiOi/j, siloxane units as indicated by the formula
R'2R2SiO|/2, as indicated by the formula R^SiOi/j and a small quantity of siloxane
units as indicated by the formula SiCU/2; organopolysiloxane copolymers comprised of
siloxane units as indicated by the formula R'3R2SiOi/2, siloxane units as indicated by
the formula R'2SiO2/2 and siloxane units as indicated by the formula SiO4/2;
organopolysiloxane copolymers comprised of siloxane units as indicated by the
formula R'R2Si02/j, siloxane units as indicated by the formula R'SiO.™ and siloxane
units as indicated by the formula R2SiO.v2, and mixtures of two or more of these
organopolysiloxanes. In the foregoing formulas, R1 is a monovalent hydrocarbon
group other than an alkenyl group, for example, an alky) group such as a methyl
group, an ethyl group, a propyl group, a butyl group, a pentyl group, a hexyl group or
a heptyl group, an aryl group such as a phenyl group, a tolyl group, a xylyl group or a
naphthyl group, an aralkyl group such as a phenethyl group or a halogenated alkyl
group such as a chloromethyl group, a 3-chloropropyl group or a 3,3,3-trifluoropropyl
group. In the foregoing formulas, R2 is an alkenyl group, for example, a vinyl group,
an ally! group, a butenyl group, a pentenyl group, a hexenyl group or a heptenyl
group.
Where utilized, the organohydrogenpolysiloxane acts as a crosslinking agent and
contains an average of at least two hydrogen atoms that are bonded to silicon atoms
per molecule. The positions of bonding of the hydrogen atoms bonded with the
silicon atoms in the organohydrogenpolysiloxane can be, for example, the terminals
of the molecular chain and/or side chains of the molecular chain. Organic groups
bonded with silicon atoms of the organohydrogenpolysiloxane include, for example,
alkyl groups such as methyl groups, ethyl groups, propyl groups, butyl groups, pentyl
groups, hexyl groups and heptyl groups, aryl groups such as phenyl groups, tolyl
groups, xylyl groups and naphthyl groups, aralkyl groups such as phenethyl groups or
halogenated alkyl groups such as chloromethyl groups, 3-chloropropyl groups or
3,3,3-trifluoropropyl groups. Methyl groups and phenyl groups are particular
preferred. The molecular structure of the organohydrogenpolysiloxane may be, for
example, in straight chain form, a straight chain form having some branches, in cyclic
form and in branched chain form, with the straight chain form being particularly
preferred. Although there is no limitation on the viscosity of the
organohydrogenpolysiloxane, a viscosity in the range of about 1 to about 500,000
centipoise at 25° C. is desirable, with a range of about 5 to about 5,000 centipoise
being particularly preferred.
The organohydrogenpolysiloxane (component B) can include, for example,
methylhydrogen polysiloxane blocked with trimethylsiloxy groups at both terminals
of the molecular chain, copolymers of dimethyl siloxane blocked with trimethylsiloxy
groups at both terminals of the molecular chain and of methylhydrogen siloxane,
copolymers of dimethyl siloxane blocked with trimethylsiloxy groups at both
terminals of the molecular chain, methylhydrogen siloxane and methylphenyl
siloxane, dimethyl polysiloxane blocked with dimethylhydrogen siloxane groups at
both terminals of the molecular chain, dimethyl polysiloxane blocked with
dimethylhydrogen siloxane groups at both terminals of the molecular chain,
copolymers of dimethyl blocked with dimethylhydrogen siloxane groups at both
terminals of the molecular chain and methylphenyl siloxane, methylphenyl
polysiloxane blocked with dimethylhydrogen siloxane groups at both terminals of the
molecular chain, organopolysiloxane copolymers comprised of siloxane units as
indicated by the formula R'.iSiO]/2 siloxane units as indicated by the formula
R^HSiOi/z and siloxane units as indicated by the formula SiO^/j, organopolysiloxane
copolymers comprised of siloxane units as indicated by the formula R'zHSiOi/? and
siloxane units as indicated by the formula SiO
Documents
Application Documents
| # |
Name |
Date |
| 1 |
997-DELNP-2006-Form-18-(27-06-2006).pdf |
2006-06-27 |
| 1 |
997-DELNP-2006_EXAMREPORT.pdf |
2016-06-30 |
| 2 |
997-delnp-2006-abstract.pdf |
2011-08-20 |
| 2 |
997-DELNP-2006-Correspondence-Others-(27-06-2006).pdf |
2006-06-27 |
| 3 |
997-delnp-2006-pct-304.pdf |
2011-08-20 |
| 3 |
997-delnp-2006-assignments.pdf |
2011-08-20 |
| 4 |
997-delnp-2006-pct-237.pdf |
2011-08-20 |
| 4 |
997-delnp-2006-claims.pdf |
2011-08-20 |
| 5 |
997-delnp-2006-pct-210.pdf |
2011-08-20 |
| 5 |
997-delnp-2006-correspondence-others.pdf |
2011-08-20 |
| 6 |
997-delnp-2006-pct-101.pdf |
2011-08-20 |
| 6 |
997-delnp-2006-description (complete).pdf |
2011-08-20 |
| 7 |
997-delnp-2006-form-5.pdf |
2011-08-20 |
| 7 |
997-delnp-2006-drawings.pdf |
2011-08-20 |
| 8 |
997-delnp-2006-form-1.pdf |
2011-08-20 |
| 8 |
997-delnp-2006-form-3.pdf |
2011-08-20 |
| 9 |
997-delnp-2006-form-2.pdf |
2011-08-20 |
| 10 |
997-delnp-2006-form-3.pdf |
2011-08-20 |
| 10 |
997-delnp-2006-form-1.pdf |
2011-08-20 |
| 11 |
997-delnp-2006-form-5.pdf |
2011-08-20 |
| 11 |
997-delnp-2006-drawings.pdf |
2011-08-20 |
| 12 |
997-delnp-2006-pct-101.pdf |
2011-08-20 |
| 12 |
997-delnp-2006-description (complete).pdf |
2011-08-20 |
| 13 |
997-delnp-2006-pct-210.pdf |
2011-08-20 |
| 13 |
997-delnp-2006-correspondence-others.pdf |
2011-08-20 |
| 14 |
997-delnp-2006-pct-237.pdf |
2011-08-20 |
| 14 |
997-delnp-2006-claims.pdf |
2011-08-20 |
| 15 |
997-delnp-2006-pct-304.pdf |
2011-08-20 |
| 15 |
997-delnp-2006-assignments.pdf |
2011-08-20 |
| 16 |
997-DELNP-2006-Correspondence-Others-(27-06-2006).pdf |
2006-06-27 |
| 16 |
997-delnp-2006-abstract.pdf |
2011-08-20 |
| 17 |
997-DELNP-2006_EXAMREPORT.pdf |
2016-06-30 |
| 17 |
997-DELNP-2006-Form-18-(27-06-2006).pdf |
2006-06-27 |