HIGH ASPECT BORON NITRIDE, METHODS, AND COMPOSITION CONTAINING THE SAME

• US 20160325994A1
• Filed: 01/05/2015
• Published: 11/10/2016
• Est. Priority Date: 01/06/2014
• Status: Abandoned Application

• Current Assignee: Momentive Performance Materials Incorporated (Momentive Performance Materials Holdings LLC)
• Original Assignee: Momentive Performance Materials Incorporated (Momentive Performance Materials Holdings LLC)
• Inventors: QU, Hao, MURUGAIAH, Anand, XIANG, Bei, RAMAN, Chandrashekar, YI-LIN, Kang
• Application Number:
  US15/109,869
• Publication Number:
  US 20160325994A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: C01B 21/0648 After-treatment, e.g. grinding, purification transformation of hexagonal into cubic or wurtzitic boron nitride C04B35/5831
• CPC Class Codes: C01B 35/146 Compounds containing boron and nitrogen, e.g. borazoles ammonium tetrafluoborates C01B35/063; ammonium borates C01B35/12
• CPC Class Codes: C01P 2004/03 obtained by SEM
• CPC Class Codes: C01P 2004/54 Particles characterised by their aspect ratio, i.e. the ratio of sizes in the longest to the shortest dimension
• CPC Class Codes: C01P 2004/61 Micrometer sized, i.e. from 1-100 micrometer
• CPC Class Codes: C01P 2004/62 Submicrometer sized, i.e. from 0.1-1 micrometer
• CPC Class Codes: C01P 2006/12 Surface area
• CPC Class Codes: C04B 2235/386 Boron nitrides
• CPC Class Codes: C04B 2235/5292 Flakes, platelets or plates
• CPC Class Codes: C04B 2235/5296 with a defined aspect ratio, e.g. indicating sphericity spherical constituents C04B2235/528
• CPC Class Codes: C04B 2235/5409 expressed by specific surface values
• CPC Class Codes: C04B 2235/5436 micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/723 Oxygen content
• CPC Class Codes: C04B 2235/767 Hexagonal symmetry, e.g. beta-Si3N4, beta-Sialon, alpha-SiC or hexa-ferrites
• CPC Class Codes: C04B 35/583 based on boron nitride
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C08K 2003/385 Binary compounds of nitrogen with boron
• CPC Class Codes: C08K 3/38 Boron-containing compounds
• CPC Class Codes: C09D 1/00 Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
• CPC Class Codes: C09D 5/084 Inorganic compounds
• CPC Class Codes: C09K 5/10 : Liquid materials
• CPC Class Codes: C09K 5/14 : Solid materials, e.g. powdery or granular
• CPC Class Codes: C10M 125/26 : Compounds containing silicon or boron, e.g. silica, sand
• CPC Class Codes: C10M 2201/087 : Boron oxides, acids or salts
• CPC Class Codes: C10N 2020/06 : Particles of special shape or size
• CPC Class Codes: C22C 29/16 : based on nitrides containing cubic BN or wurtzitic BN and diamond C22C26/00
• CPC Class Codes: C22C 32/0068 : only nitrides
• CPC Class Codes: H01B 3/02 : mainly consisting of inorganic substances

Abstract

A multi-functional composition including high aspect boron nitride particles providing improved properties such as thermal conductivity, electrical insulation, barrier to moisture, vapor, and gasses, lubrication, friction modification, optical properties, suspension stability, and a system and method for forming such compositions. The high boron nitride particles have an average aspect ratio greater than 300. The multifunctional composition may comprise of a polymer material, fluids, metals, ceramics, glasses, other non-BN fillers and the high aspect ratio boron nitride. Also provided are methods for making such boron nitride particles and compositions.

Claims

1. A composition comprising boron nitride particles with an average aspect ratio of greater than 300.

2. The composition of claim 1, wherein the boron nitride particles have an average aspect ratio of about 305 to about 2500.

3. The composition of claim 1, wherein at least 25% of the boron nitride particles have an average aspect ratio of greater than 300.

4. The composition of claim 1, wherein the boron nitride particles have x-y dimensions in the range of 0.1 microns to 5 millimeters

5. The composition of claim 1, wherein the boron nitride particles have an average particle size of about 0.1 μ

m to 500 μ

m.

6. The composition of claim 1, wherein the boron nitride particles comprise h-BN particles having a graphitization index of less than 7.

7. The composition of claim 1, wherein the boron nitride particles have an oxygen content from about 0.05 to about 5 wt. %.

8. The composition of claim 1, wherein the boron nitride particles have a surface area of from about 5 m²/g to about 500 m²/g.

9. The composition of claim 1, wherein the boron nitride particles are chosen from semi-crystalline or turbostratic boron nitride, hexagonal boron nitride, or a combination of two or more thereof.

10. The composition of claim 1, wherein the boron nitride particles are chosen from, turbostratic boron nitride, platelet hexagonal boron nitride, agglomerated boron nitride particles, or a combination of two or more thereof.

11. The composition of claim 1, wherein the composition further comprises a polymer chosen from a thermoset material, a thermoplastic material, or a combination thereof.

12. The composition of claim 11, where in the composition comprises a total boron nitride loading from about 0.1 wt % to 75 wt %.

13. The composition of claim 1, wherein the composition further comprises a filler chosen from boron nitride;

silica;

glass fibers;

zinc oxide;

magnesia;

titania;

yttrium oxide;

hafnium oxide;

calcium carbonate;

talc;

mica;

wollastonite;

alumina;

aluminum nitride;

metallic powders, such as aluminum, copper, bronze, brass;

fibers or whiskers of carbon, graphite, silicon carbide, silicon nitride, alumina, aluminum nitride, zinc oxide;

nano-scale fibers, chosen from carbon nanotubes/nano-fibers, cellulose fibers, graphene, boron nitride nanotubes/nano-fibers, zinc oxide nanotubes/nano-fibers;

oxides belonging to the alkaline and alkaline earth elements;

transition metal oxides;

oxides from post-transition metals;

oxides from metalloids;

oxides from the lanthanide and actinide series of elements;

complex oxides;

carbides belonging to transition elements;

carbides belonging to metalloid elements;

carbides belonging to lanthanide and actinide series of elements;

nitrides belonging to transition elements;

nitrides belonging to post transition elements;

nitrides belonging to metalloid elements;

nitrides belonging to the lanthanide and actinide series of elements, metals, metalloids, carbon;

or a combination or two or more of any of these materials.

14. The composition of claim 1, wherein the composition has a through-plane thermal conductivity of at least 0.3 W/mK at a loading of 25 wt % BN or less.

15. The composition of claim 1, wherein the composition has an in-plane thermal conductivity of at least 0.3 W/mK at a loading of 25 wt % BN or less.

16. The composition of claim 1, wherein the composition has a through-plane thermal conductivity from about 0.3 W/mK to 30 W/mK.

17. The composition of claim 1, wherein the composition has an in-plane thermal conductivity from about 0.3 W/mK to 30 W/mK.

18. The composition of claim 1, wherein the composition further comprises a fluid chosen from an oil, water, an organic, or a combination of two or more thereof, with or without other BN and non-BN fillers.

19. The composition of claim 1, wherein the composition further comprises a metal or a combination of metals/alloys thereof, with or without other BN and non-BN fillers.

20. The composition of claim 1, wherein the composition further comprises an inorganic matrix chosen from a ceramics, a boride, a glass, or a combination of two or more thereof, with or without other BN and non-BN fillers.

21. The composition of claim 1, wherein the composition further comprises a fibrous preform chosen from cellulose, BN fibers, glass fibers, or a combination of two or more thereof, with or without other BN and non-BN fillers.

22. The composition of claim 1 comprising a matrix material chosen from chosen from a siloxane, a silane, a polyesters, a vinyl polymer, an acrylate, a urethane, an epoxy, a polyamide, a polyimide, a polyamidimide, a polycarbonate, a polypthalamide, a polysulfone, a polyetheretherketone, a thermoplastic polyurethane, a fluoropolymer, a fluoroelastomer, a chlorofluoropolymer, a chloropolymers, a phenol-formaldehyde resin, an aramid polymer, a melamine resin, a polyethylene terephthalate, or a combination of two or more thereof

35. An article comprising the composition of claim 1.

36. The article of claim 35, wherein at least a portion of the article is formed from the composition.

38. The article of any of claim 35, wherein the article is chosen from

any one or a combination of the following:

encapsulants for LEDs, blends into the phosphor layer, blends into the remote phosphor, and blends into the encapsulant layer in LEDs, thermal interface materials (TIMS), solid-state device packaging materials, photon-conversion layers, phosphorescent materials, transparent materials, diffuse/scattering materials, reflective and whitening agents (reflection of all color), LED packaging substrates with similar CTE as silicone encapsulants enabling minimizing delamination failures, polymer housings for luminaires, heat sinks, thermofluids, structural materials, gas/vapor/moisture barrier materials, thermoelectric materials, electronics, computers, mobile devices, medical equipment, automotive, industrial, lighting, off-shore, lasers, and aerospace.

23. A process for making high aspect ratio boron nitride particles, the process comprising treating a boron nitride starting material under mechanical shear suspended in a carrier, wherein the carrier is in a liquid form, a solid form, or a combination of solid and liquid phases to produce boron nitride particles having an average aspect ratio greater than 300.

24. The process of claim 23, wherein the boron nitride particles have an average aspect ratio of about 300 to about 2500.

25. The process of claim 23, wherein at least 20% of the boron nitride particles have an average aspect ratio of greater than 300.

26. The process of claim 23, wherein the boron nitride particles are chosen from platelet hexagonal boron nitride, turbostratic boron nitride, agglomerated boron nitride particles, or a combination of two or more thereof.

27. The process of claim 23, wherein mechanical shear is applied to the BN particles in the carrier via processes chosen from extrusion, kneading, fluid flow in micro-channels, or a combination of two or more thereof wherein shear forces are more prominent than impact or other type of forces.

28. The process of claim 23, wherein the boron nitride starting material is pre-treated prior to mechanical exfoliation.

29. The process of claim 23, wherein treating the boron nitride starting material comprises subjecting the boron nitride starting material to a chemical exfoliation process.

30. A boron nitride particle having an average aspect ratio of 300 or greater.

31. The boron nitride particle of claim 30, wherein the boron nitride particles have an average aspect ratio of about 305 to about 2500.

32. The boron nitride particle of claim 30, wherein the boron nitride particle is treated with a surface treatment agent, chosen from a surface functional agent, a coupling agent, a dispersant, or a combination of two or more thereof.

33. The boron nitride of claim 32, wherein the surface treatment agent is chosen from an epoxy monomer, a silane, a silicone, a zirconate, an oleate, a phosphate, or a combination of two or more thereof.

34. The boron nitride of claim 33, wherein the surface treatment agent comprises a silicone, silane chosen from an alkacryloxy silane, a vinyl silane, a halo silane, a mercapto silane, a thiocarboxylate silane;

a blocked mercapto silane;

3-octanoylthio-1-propyltriethoxy silane, vinyl tris(2-methoxy-ethoxy)silane, gamma-methacryloxypropyltreimethoxy silane, mercaptosilane;

an alkacryloxy silane;

a vinyl silane;

a halo silane;

a thicaraboxylate silane;

or a combination of two or more thereof.

37. The article of claim 34 wherein the composition is disposed on at least a portion of a surface of the article.