Thermal Interface Material with Aligned Carbon Nanotubes

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Solution Overview

Problem

Conventional thermal interface materials with carbon nanotubes suffer from high thermal resistance due to random orientation and air pockets, which hinder effective heat dissipation in modern electronic components.

Innovation Solution

A method involving a carbon nanotube array with interstices is used, where a liquid base material is filled and cured in situ, followed by submersion in a second base material, ensuring alignment and minimal air, thus maintaining uniform orientation and complete contact for reduced thermal resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If carbon nanotubes are filled in a base material randomly, then the manufacturing process is simple, but the thermal resistance increases due to multiple junction points

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidthermal resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The carbon nanotubes are pre-aligned in a specific orientation within the base material before final curing, rather than being randomly distributed. This preliminary arrangement of nanotubes in a controlled orientation reduces the number of junction points in heat conduction paths, thereby reducing thermal resistance while maintaining manufacturing feasibility

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the orientation parameter of carbon nanotubes from random to aligned configuration. By controlling the spatial arrangement and orientation of nanotubes during the manufacturing process, the thermal conduction performance is significantly improved by minimizing thermal resistance at junction points

Inventive Principle:

Principle #35Parameter changes

2Reliability

If an electrical field is applied to orient carbon nanotubes, then thermal resistance decreases, but asymmetric distribution occurs due to field variations

Engineering Contradiction:

Improvethermal resistanceVSAvoidcarbon nanotube distribution uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent introduces a liquid crystal material as an intermediary medium that facilitates the alignment of carbon nanotubes. The liquid crystal provides a uniform orienting environment that eliminates the asymmetric distribution problems associated with direct electrical field application, while still achieving the desired nanotube alignment for reduced thermal resistance

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the electrical field mechanism with a liquid crystal-based alignment mechanism. This substitution eliminates the issues of field intensity and direction variations, providing a more uniform and controllable alignment process that maintains both thermal performance and distribution uniformity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If air exists in thermal interface structure, then manufacturing is easier, but thermal resistance increases due to incomplete contact

Engineering Contradiction:

Improvemanufacturing easeVSAvoidthermal resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent utilizes phase transition of the base material from liquid to solid state during curing. This phase transition enables the material to completely fill and contact the carbon nanotube array, eliminating air pockets and voids. The liquid state allows easy infiltration, while the solid state provides structural integrity and complete contact for optimal thermal conduction

Inventive Principle:

Principle #36Phase transitions

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method results in a thermal interface material with low overall thermal resistance, effectively addressing the limitations of conventional materials by maintaining carbon nanotube alignment and minimizing air pockets for enhanced heat dissipation.

Implementation Method 1

filling a liquid state first base material into the interstices

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

the first base material melting and flowing out of the carbon nanotube/first base material composite

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

carbon nanotubes that conduct heat

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS8048322B2Method for manufacturing thermal interface material having carbon nanotubes

Publication Date: 2011.11.01 HON HAI PRECISION INDUSTRY CO LTD

AI summary

A method for manufacturing a thermal interface material includes the following steps: providing a carbon nanotube array formed on a substrate, the carbon nanotube array having a number of carbon nanotubes and a number of interstices between the adjacent carbon nanotubes; filling a liquid state first base material into the interstices; curing the first base material, thereby achieving a carbon nanotube/first base material composite; dripping a liquid state second base material onto the surface of the carbon nanotube/first base material composite, the first base material melting and flowing out of the carbon nanotube/first base material composite, until the carbon nanotube array being substantially submerged in the second base material; and curing the second base material, thereby achieving a thermal interface material.