Carbon Nanotube Composite Thermal Interface Material
Solution Overview
Problem
Existing thermal interface materials (TIMs) face challenges in conforming to subtle surface bumps and dents on electronic components and heat sinks, leading to gaps and reduced thermal conductivity, and the use of carbon nanotubes in TIMs struggles with adhesive strength and long-term thermal conductivity.
Innovation Solution
A carbon nanotube composite material is developed, featuring a fixture sheet with a carbon nanotube array sheet embedded or bonded on both sides, which conforms to surface irregularities and is densified to enhance thermal conductivity, with optional resin layers and conductive substrates to prevent nanotube dropout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a polymer sheet is used as TIM, then the structure is simple and easy to manufacture, but it cannot conform to subtle surface bumps and dents, leading to gaps and reduced thermal conductivity
Solution Approach 1:
The patent uses a composite structure combining a polymer substrate with carbon nanotube arrays. The polymer provides structural support and ease of manufacture, while the carbon nanotubes provide conformability to surface irregularities and high thermal conductivity, resolving the contradiction between ease of manufacture and thermal conductivity performance
2Reliability
If silicone grease is used as TIM, then it can conform to subtle surface bumps and dents, but repetitive temperature changes cause pumping out, making it difficult to secure long-term thermal conductivity
Solution Approach 1:
The patent combines silicone grease with a carbon nanotube array structure. The silicone grease fills micro-gaps and provides initial conformability, while the carbon nanotube array provides structural integrity and prevents pumping out during thermal cycling, ensuring long-term durability while maintaining conformability
3Reliability
If carbon nanotube array sheet is embedded in fixture sheet, then nanotube dropout is suppressed and thermal conductivity is maintained, but the manufacturing process becomes more complex
Solution Approach 1:
The patent pre-forms the carbon nanotube array sheet before embedding it in the fixture sheet. This preliminary preparation allows the complex carbon nanotube structure to be manufactured separately and then integrated into the final assembly, reducing overall manufacturing complexity while maintaining the benefits of suppressed nanotube dropout and sustained thermal conductivity
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 carbon nanotube composite material effectively conforms to surface features, maintains thermal conductivity over time, and prevents nanotube dropout, improving the reliability and efficiency of heat transfer between electronic components and heat sinks.
Implementation Method 1
the carbon nanotube array sheet are allowed to conform to the subtle dents and bumps of the object surface
Implementation Method 2
efficiently conduct heat generated from the electronic component to the heat sink
Data Source
AI summary
A carbon nanotube composite material includes a fixture sheet having a front side and a back side, and a carbon nanotube array sheet embedded in or bonded to both front and back sides of the fixture sheet.