Highly thermally conductive yet highly conformable alumina filled composition and method of making the same
First Claim
1. A method of making a thermally conductive and conformable composition, comprising the steps of:
- (a) providing 100 parts by weight of a gel; and
(b) combining the gel with between 150 and 400 parts by weight of α
-alumina, wherein at least 10 percent by weight of the α
-alumina has a particle size of at least 74 μ
m, to form a combination of the gel material and the α
-alumina; and
(c) mixing the combination to make the thermally conductive and conformable composition.
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Accused Products
Abstract
A highly thermally conductive but yet highly conformable composition is made from gel filled with alumina. The use of α-alumina in which at least 10 weight % of the α-alumina particles have a particle size of at least 74 μm makes possible the high filler levels needed to attain high thermal conductivity, without causing the decrease in elongation and softness normally associated with high filler levels. Further improvements are observed if the α-alumina and the gel (or precursor thereof) are mixed with a specific energy input of at least 10 Joule/g. The input of such specific energy has the effect making the resulting composition more conformable than it otherwise would be. The composition may be internally supported by a flexible matrix such as a fabric or open-celled foam.
53 Citations
21 Claims
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1. A method of making a thermally conductive and conformable composition, comprising the steps of:
-
(a) providing 100 parts by weight of a gel; and (b) combining the gel with between 150 and 400 parts by weight of α
-alumina, wherein at least 10 percent by weight of the α
-alumina has a particle size of at least 74 μ
m, to form a combination of the gel material and the α
-alumina; and(c) mixing the combination to make the thermally conductive and conformable composition. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A method of making a thermally conductive and conformable composition, comprising the steps of:
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(a) providing 100 parts by weight of a precursor material curable into a gel; (b) combining the precursor material with between 150 and 400 parts by weight of α
-alumina, wherein at least 10 percent by weight of the α
-alumina has a particle size of at least 74 μ
m, to form a combination of the precursor material and the α
-alumina; and(c) curing the precursor material into a gel to form the thermally conductive and conformable composition. - View Dependent Claims (8, 9)
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10. A method of making a thermally conductive and conformable composition, comprising the steps of:
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(a) separately providing first and second precursor components, which when mixed together cure to form a gel, the combined amounts of the first and the second precursor components totaling 100 parts by weight; (b) separately combining α
-alumina with each of the first and second precursor components to form respective first and second combinations comprising α
-alumina and a first or second precursor component respectively, wherein at least 10 weight percent of the α
-alumina has a particle size of at least 74 μ
m and the total amount of α
-alumina is between 150 and 400 parts by weight; and(c) mixing the first and second combinations and curing to form the thermally conductive and conformable composition. - View Dependent Claims (11, 12)
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13. A conformable and thermally conductive composition, comprising
(a) 100 parts by weight of a gel and (b) between 150 and 400 parts by weight of α - -alumina, wherein at least 10 weight percent of the α
-alumina has a particle size of at least 74 μ
m. - View Dependent Claims (14, 15, 16, 17, 18)
- -alumina, wherein at least 10 weight percent of the α
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19. An article comprising
(I) a conformable and thermally conductive composition, comprising (a) 100 parts by weight of a gel and (b) between 150 and 400 parts by weight of α - -alumina, wherein at least 10 weight percent of the α
-alumina has a particle size of at least 74 μ
m; and(II) a flexible matrix internally supporting the composition. - View Dependent Claims (20, 21)
- -alumina, wherein at least 10 weight percent of the α
Specification