Patent Description:
With the significant improvement in performance of semiconductor devices such as CPUs in recent years, the amount of heat generated by them has become extremely large. For this reason, heat dissipating materials are attached to electronic components that may generate heat, and a thermally conductive silicone grease is used to improve the adhesion between the heat dissipating materials and heat generating members such as semiconductor devices. The thermally conductive silicone grease has been required to have high thermal conductive properties and drop resistance as devices become smaller in size, more sophisticated, and more highly integrated Patent Document <NUM> proposes a composition that includes a thermally conductive filler, a polyorganosiloxane resin containing at least one polysiloxane having one curable functional group in the molecule, and a siloxane compound having an alkoxysilyl group and a linear siloxane structure. Patent Document <NUM> proposes a thermally conductive silicone composition that includes a liquid silicone, a thermally conductive filler, and hydrophobic spherical silica fine particles, and that has high heat dissipation properties. Patent Document <NUM> proposes a fluorine-containirig adhesive composition that includes alumina with different particle sizes and shapes (see paragraph [<NUM>]). Patent Document <NUM> proposes a thermally conductive silicone composition comprising an alkenyl group-containing organopolysiloxane, an organohydrogen polysiloxane, a hydrosilylation reaction catalyst, a thermally conductive filler, an alkoxysilane and glass beads. Patent Document <NUM> proposes a polymer having a siloxane polymer backbone and compositions comprising the same. Patent Document <NUM> proposes a thermally conductive silicone composition comprising an ionically modified siloxane and a thermally conductive filler comprising a first filler and a second filler where the first filler and/or the second filler comprise a plurality of filler types differing in terms of particle size and/or morphology. Patent Document <NUM> proposes a highly thermally conductive silicone composition including an organopolysiloxane, a spherical aluminium oxide powder, and a spherical or amorphous aluminium oxide powder. Patent Document <NUM> proposes a resin composition comprising a boron nitride filler. Patent Document <NUM> proposes thermally conductive compositions containing spherical boron nitride filler particles. Patent Document <NUM> proposes a heat conductive silicone composition which contains a silicone oil and a heat conductive filler.

However, the viscosity or specific gravity of the conventional thermally conductive silicone grease increases in proportion to the thermal conductivity.

To solve the above conventional problems, the present invention provides a thermally conductive silicone grease composition that has a high thermal conductivity, but still has a relatively low specific gravity, and that also has a viscosity for good workability and good coating properties. Moreover, the present invention provides a method for producing the thermally conductive silicone grease composition.

A thermally conductive silicone grease composition of the present invention is a non-curable thermally conductive silicone grease composition and includes: A <NUM> parts by mass of a non-curable silicone oil with a kinematic viscosity of <NUM> to <NUM><NUM>/s at <NUM>; and B. <NUM> to <NUM> parts by mass of thermally conductive particles with respect to <NUM> parts by mass of the component A The thermally conductive particles contain the following: B <NUM> to <NUM> parts by mass of irregularly-shaped alumina with a median particle size of <NUM> to <NUM>, in which a part or all of the alumina is surface pre-treated with an alkoxysilane compound expressed by RaSi(OR')<NUM>-a (where R represents a substituted or unsubstituted alkyl group having <NUM> to <NUM> carbon atoms, R' represents an alkyl group having <NUM> to <NUM> carbon atoms, and a represents <NUM> or <NUM>) or a partial hydrolysate of the alkoxysilane compound; B2. <NUM> to <NUM> parts by mass of plate-like boron nitride with a median particle size of <NUM> to <NUM>; and B3. <NUM> to <NUM> parts by mass of aggregated boron nitride with a median particle size of <NUM> to <NUM>. Ablending ratio of the component B3 to the component B2 is <NUM> to <NUM>.

A method for producing a thermally conductive silicone grease composition of the present invention includes mixing <NUM> to <NUM> parts by mass of thermally conductive particles (B) with <NUM> parts by mass of a non-curable silicone oil (A) with a kinematic viscosity of <NUM> to <NUM><NUM>/s at <NUM>. The thermally conductive particles contain the following: B <NUM> to <NUM> parts by mass of irregularly-shaped alumina with a median particle size of <NUM> to <NUM>, in which a part or all of the alumina is surface pre-treated with an alkoxysilane compound expressed by RaSi(OR')<NUM>, (where R represents a substituted or unsubstituted alkyl group having <NUM> to <NUM> carbon atoms, R' represents an alkyl group having <NUM> to <NUM> carbon atoms, and a represents <NUM> or <NUM>) or a partial hydrolysate of the alkoxysilane compound; B2. <NUM> to <NUM> parts by mass of plate-like boron nitride with a median particle size of <NUM> to <NUM>; and B3. <NUM> to <NUM> parts by mass of aggregated boron nitride with a median particle size of <NUM> to <NUM>. Ablending ratio of the component B3 to the component B2 is <NUM> to <NUM>.

In the present invention, the irregularly-shaped alumina, the plate-like boron nitride, and the aggregated boron nitride, each of which has a specific p article size, are combined and mixed together, thus providing the thermally conductive silicone grease composition that can have a high thermal conductivity, but still have a relatively low specific gravity, and that can also have a viscosity for good workability and good coating properties. Moreover, the thermally conductive silicone grease composition is non-curable and does not cause any change in the properties during storage and after use, resulting in better storage stability.

[<FIG> are diagrams illustrating a method for measuring a thermal conductivity of a sample in an example of the present invention.

The thermally conductive silicone grease composition of the present invention is a non-curable thermally conductive silicone grease composition. Therefore, a curing catalyst and a curing agent are not necessary, but may be added in some cases. The non-curable silicone oil is used as a matrix resin. The silicone oil and the thermally conductive particles are basic components and are mixed in the following proportions. The component A and the component B, and optionally other components, are mixed to form a grease.

The kinematic viscosity of the component A is preferably <NUM> to <NUM><NUM>/s, more preferably <NUM> to <NUM><NUM>/s, and further preferably <NUM> to <NUM><NUM>/s at <NUM>.

The amount of the component B is preferably <NUM> to <NUM> parts by mass, and more preferably <NUM> to <NUM> parts by mass with respect to <NUM> parts by mass of the component A.

The thermally conductive particles contain the following:.

The blending ratio of the component B3 to the component B2 is <NUM> to <NUM>.

In this case, the term "part" of the alumina means <NUM>% by mass or more.

The amount of the component B1 is preferably <NUM> to <NUM> parts by mass, and more preferably <NUM> to <NUM> parts by mass with respect to <NUM> parts by mass of the component A.

The amount of the component B2 is preferably <NUM> to <NUM> parts by mass, and more preferably <NUM> to <NUM> parts by mass with respect to <NUM> parts by mass of the component A.

The amount of the component B3 is preferably <NUM> to <NUM> parts by mass, and more preferably <NUM> to <NUM> parts by mass with respect to <NUM> parts by mass of the component A.

The blending ratio of the component B3 to the component B2 (B3/B2) is preferably <NUM> to <NUM>, and more preferably <NUM> to <NUM>. With this configuration, small-size particles are present between large-size particles, which can approximate the closest packing and improve the thermal conductive properties.

The thermally conductive silicone grease composition preferably further includes <NUM> to <NUM> parts by mass of an alkoxysilane compound expressed by RaSi(OR')<NUM>-a (where R represents a substituted or unsubstituted alkyl group having <NUM> to <NUM> carbon atoms, R' represents an alkyl group having <NUM> to <NUM> carbon atoms, and a represents <NUM> or <NUM>) as a component C. This can reduce the viscosity of the composition.

The thermal conductivity of the thermally conductive silicone grease composition is preferably <NUM> W/m-K or more and <NUM> W/m-K or less, more preferably <NUM> to <NUM> W/m-K, and further preferably <NUM> to <NUM> W/m-K This thermally conductive grease is suitable as a TIM (thermal interface material).

The specific gravity of the thermally conductive silicone grease composition is preferably <NUM> or more and <NUM> or less, more preferably <NUM> to <NUM>, and further preferably <NUM> to <NUM>. Thus, the silicone grease with a lower specific gravity is obtained, which can reduce the weight of the entire electronic components.

The absolute viscosity of the thermally conductive silicone grease composition is preferably <NUM> to <NUM> Pas, more preferably <NUM> to <NUM> Pas, and further preferably <NUM> to <NUM> Pas at <NUM>, which is measured with a B-type viscometer using a T-E spindle at a rotational speed of <NUM> rpm. This can improve the workability of the thermally conductive silicone grease composition, and can also facilitate the insertion or application of the thermally conductive silicone grease composition between the heat generating member and the heat dissipating material. Moreover, the thermally conductive silicone grease composition is non-curable and does not cause any change in the properties during storage and after use, resulting in better storage stability.

In the present invention, the reason that the components B1, B2, and B3 are mixed with the component A in the above proportions is to allow small-size particles to fill the space between large-size particles so that the closest packing can be approximated to enhance the thermal conductive properties. The particle size is measured with a laser diffraction scattering method to determine D50 (median diameter) in a volume-based cumulative particle size distribution. The method may use, e.g., a laser diffraction/scattering particle size distribution analyzer LA-<NUM> S2 manufactured by HORIBA, Ltd.

A part or all of the irregularly-shaped alumina with a median particle size of <NUM> to <NUM> (component B1) is surface pre-treated with an alkoxysilane compound expressed by RaSi(OR')<NUM>-a (where R represents a substituted or unsubstituted alkyl group having <NUM> to <NUM> carbon atoms, R' represents an alkyl group having <NUM> to <NUM> carbon atoms, and a represents <NUM> or <NUM>) or a partial hydrolysate of the alkoxysilane compound Examples of the alkoxysilane compound include octyltrimethoxysilane, octyltriethoxysilane, decyltiimethoxysilane, decyltriethoxysilane, dodecyltrimethoxysilane, and dodecyltriethoxysilane. In particular, the carbon number of the alkyl group represented by R is within a preferred range of <NUM> to <NUM>, and the alkoxysilane compound is in a liquid state and has water repellency and a high affinity for the silicone oil. These silane compounds may be used alone or in combination of two or more. The alkoxysilane and one-end silanol siloxane may be used together as a surface treatment agent. In this case, the surface treatment may include adsorption in addition to a covalent bond.

The irregularly-shaped alumina with a median particle size of <NUM> to <NUM> (component B1) cannot be easily mixed with the silicone oil if it is not subjected to any treatment. However, the irregularly-shaped alumina that has been pretreated, i.e., surface treated with the alkoxysilane compound is easily mixed with the silicone oil, so that a uniform composition can be obtained It is preferable that <NUM> to <NUM> parts by mass of the alkoxysilane compound is added to <NUM> parts by mass of the irregularly-shaped alumina with a median particle size of <NUM> to <NUM>. The pretreatment means that the thermally conductive particles are surface treated with the surface treatment agent in advance before mixing the thermally conductive particles and the silicone oil.

The thermally conductive particles other than the component B1 may be either pretreated or not pretreated, since the mixability will not be reduced even if the pretreatment is not performed.

The grease of the present invention may include components other than the above as needed. For example, a heat resistance improver (such as colcothar, titanium oxide, or cerium oxide), a flame retardant, and a flame retardant auxiliary may be added Moreover, an organic or inorganic particle pigment may be added for the purpose of coloring and toning. An alkoxy group-containing silicone may be added as a material, e.g., for the surface treatment of a filler.

The thermally conductive silicone grease composition of the present invention may be put into, e.g., a dispenser, a bottle, a can, or a tube and offered as a commercial product.

A method for producing a thermally conductive silicone grease composition of the present invention includes mixing <NUM> to <NUM> parts by mass of thermally conductive particles (B) with <NUM> parts by mass of a non-curable silicone oil (A) with a kinematic viscosity of <NUM> to <NUM><NUM>/s at <NUM>. The thermally conductive particles contain the following: B <NUM>. <NUM> to <NUM> parts by mass of irregularly-shaped alumina with a median particle size of <NUM> to <NUM>, in which a part or all of the alumina is surface pre-treated with an alkoxysilane compound expressed by RaSi(OR')<NUM>-a (where R represents a substituted or unsubstituted alkyl group having <NUM> to <NUM> carbon atoms, R' represents an alkyl group having <NUM> to <NUM> carbon atoms, and a represents <NUM> or <NUM>) or a partial hydrolysate of the alkoxysilane compound; B2. <NUM> to <NUM> parts by mass of plate-like boron nitride with a median particle size of <NUM> to <NUM>; and B3. <NUM> to <NUM> parts by mass of aggregated boron nitride with a median particle size of <NUM> to <NUM>.

The above material components may be mixed, e.g., in a planetary mixer. If the mixture is too viscous to be uniformly dispersed with the planetary mixer, it is preferable that the mixture is further kneaded using two rolls. The planetary mixer has two blades that make a planetary motion, in which each blade revolves as it rotates on its axis.

Hereinafter, the present invention will be described by way of examples. However, the present invention is not limited to the following examples. Various parameters were measured in the following manner.

The thermal conductivity of a thermally conductive grease was measured by a hot disk (in accordance with ISO/CD <NUM>-<NUM>). As shown in <FIG>, using a thermal conductivity measuring apparatus <NUM>, a polyimide film sensor <NUM> was sandwiched between two samples 3a, 3b, and constant power was applied to the sensor <NUM> to generate a certain amount of heat. Then, the thermal characteristics were analyzed from the value of a temperature rise of the sensor <NUM>. The sensor <NUM> has a tip <NUM> with a diameter of <NUM>. As shown in <FIG>, the tip <NUM> has a double spiral structure of electrodes. Moreover, an electrode <NUM> for an applied current and an electrode <NUM> for a resistance value (temperature measurement electrode) are located on the lower portion of the sensor <NUM>. The thermal conductivity was calculated by the following formula (<NUM>).

The absolute viscosity of the grease was measured with a B-type viscometer (Brookfield HB DV2T). The B-type viscometer used a T-E spindle to measure the absolute viscosity at a rotational speed of <NUM> rpm and <NUM>.

A non-curable silicone oil (dimethylpolysiloxane) with a kinematic viscosity of <NUM><NUM>/s at <NUM> was used in the proportions as shown in Table <NUM>.

Table <NUM> shows the amount of each type of the thermally conductive particles added.

Decyltrimethoxysilane was added in the amount as shown in Table <NUM>.

The silicone oil and the thermally conductive particles were placed in a planetary mixer and mixed together at <NUM> for <NUM> minutes to form a thermally conductive silicone grease composition.

The grease thus obtained was evaluated Table <NUM> shows the conditions and results.

The results confirmed that the thermally conductive silicone grease compositions of Examples <NUM> to <NUM> had a high thermal conductivity, but still had a relatively low specific gravity, and also had a viscosity for good workability. In Comparative Example <NUM>, the specific gravity was high because all the thermally conductive particles were composed of alumina. In Comparative Example <NUM>, the viscosity was high because the B3/B2 blending ratio was outside the range of <NUM> to <NUM>.

Claim 1:
A thermally conductive silicone grease composition that is non-curable, comprising:
A. <NUM> parts by mass of a non-curable silicone oil with a kinematic viscosity of <NUM> to <NUM><NUM>/s at <NUM>; and
B. <NUM> to <NUM> parts by mass of thermally conductive particles with respect to <NUM> parts by mass of the component A,
wherein the thermally conductive particles contain the following:
B1. <NUM> to <NUM> parts by mass of irregularly-shaped alumina with a median particle size of <NUM> to <NUM>, in which a part or all of the alumina is surface pre-treated with an alkoxysilane compound expressed by RaSi(OR')<NUM>-a, where R represents a substituted or unsubstituted alkyl group having <NUM> to <NUM> carbon atoms, R' represents an alkyl group having <NUM> to <NUM> carbon atoms, and a represents <NUM> or <NUM>, or a partial hydrolysate of the alkoxysilane compound;
B2. <NUM> to <NUM> parts by mass of plate-like boron nitride with a median particle size of <NUM> to <NUM>; and
B3. <NUM> to <NUM> parts by mass of aggregated boron nitride with a median particle size of <NUM> to <NUM>, where the median particle size is measured with a laser diffraction scattering method to determine D50, the median diameter, in a volume-based cumulative particle size distribution, and
wherein a blending ratio of the component B3 to the component B2 is <NUM> to <NUM>.