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We studied certain kinds of diepoxy monomers, with so-called `mesogens'- molecular groups that cause self-ordering - and cured them with appropriate curing agents. Their thermal conductivities were up to 5 times higher than those of conventional epoxy resins. We believe that the mesogens formed nanoscopic high-order structures and the structures formed mezoscopic structures, which were covalently bound together, suppressing phonon scattering. Such resin system is therefore considered to be a kind of polymer-polymer composite with controlled nanostructures. We confirmed the existence of crystal-like structures in the epoxy resins directly by transmission electron microscope (TEM) observation. We also observed mezoscopic structures in the resins with an atomic force microscope (AFM). The results suggest a novel method to improve the thermal conductivities of insulating resins themselves by controlling the nanoscopic high-order structures.Subsequently, laminates were prepared with the developed resin composite consisting of a kind of epoxy resins with mesogens and ceramic fillers, and tested as a part of a feasibility study. The thermal conductivities of the test pieces were more than 10 times that of commercial FR-4 laminates. This result shows that controlling the nanoscopic high-order structure of the resins is effective in improving the thermal conductivity of resin composites, and the heat dissipation of electric devices as well.

High Thermal Conductive Resin Composites with Controlled Nanostructures for Electric Devices