Composite Heat Conductor with Protruding Carbon Nanostructures

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Solution Overview

Problem

Existing thermal interface materials are not reusable and have a reduced effective contact area due to microscopic surface roughness, limiting heat flow between surfaces, especially in vacuum environments where convection is not possible.

Innovation Solution

A composite material with carbon nanostructures anchored in a metal matrix is produced, allowing the carbon nanostructures to protrude from the surface, increasing the contact area and forming a releasable thermal interface with enhanced thermal conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermal interface materials are used to fill gaps between surfaces, then heat conduction is improved, but reusability is lost

Engineering Contradiction:

Improveheat conductionVSAvoidreusability

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The carbon nanostructures are designed to be mechanically detachable from the metal matrix through controlled fracturing. After use, the interface material can be separated into reusable metal matrix components and recoverable carbon nanostructures, enabling repeated application without complete replacement.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The thermal interface material is segmented into distinct functional components: a reusable metal matrix structure and detachable carbon nanostructure elements. This segmentation allows the carbon nanostructures to be recovered and reused, solving the reusability problem while maintaining heat conduction performance.

Inventive Principle:

Principle #1Segmentation

2Reliability

If surfaces are polished to increase contact area, then heat flow is improved, but microscopic roughness remains

Engineering Contradiction:

Improveheat flowVSAvoidsurface flatness

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The carbon nanostructures serve as an intermediary element between the two surfaces. They protrude from the metal matrix and make contact with the opposing surface, effectively bridging the microscopic gaps that remain after polishing. This intermediary approach compensates for residual surface roughness without requiring perfect surface flatness.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Instead of relying solely on surface flatness in the planar dimension, the solution extends into the vertical dimension by incorporating protruding carbon nanostructures. These one-dimensional structures create additional contact points that compensate for microscopic surface irregularities, effectively increasing the contact area without requiring perfect surface precision.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If carbon nanostructures are embedded in metal matrix, then thermal conductivity is enhanced, but interface reusability is reduced

Engineering Contradiction:

Improvethermal conductivityVSAvoidinterface reusability

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The interface material is designed with dynamic characteristics where the carbon nanostructures can be mechanically detached from the metal matrix through controlled fracturing. This dynamic design allows the interface to be separated into reusable components, solving the reusability problem while maintaining enhanced thermal conductivity through the carbon nanostructure-metal composite structure.

Inventive Principle:

Principle #15Dynamics

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 composite material significantly increases the heat flow between surfaces by enlarging the contact area and enabling reusability of the thermal interface, improving thermal conductivity even in vacuum conditions.

Implementation Method 1

the carbon nanostructures, preferably carbon nanotubes (CNTs), exhibit a thermal conductivity of up to 3500 W/m K along their growth direction

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

Heat flow between surfaces occurs not only via the contact surfaces, but also through the gaps between them via radiation

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentEP3821045B1Method of manufacturing a composite, composite and use of said composite as heat conductor or heat exchanger

Publication Date: 2023.05.24 FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV

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AI summary

The invention relates to a process for producing a material composite (200) comprising the steps: producing (S100) a composite material (20) that extends along an axis of elongation (z), composed of carbon nanostructures anchored in a matrix of a first metal (24), preferably carbon nanostructures (22) wherein the carbon nanostructures (22) extend along the axis of elongation (z) of the composite material (20); subdividing (S200) the composite material (20) into segments (30) of the composite material (20); arranging (S400) the segments (30) in a plane of a die (100); filling (S500) cavities in the die (120) with a filler material (130); sintering (S600) in the die (100) to form a material composite (200), and exposing the carbon nanostructures (22) of the composite material (20) on at least one surface of the composite material (200), so that the carbon nanostructures (22) project from this surface. Also proposed are a material composite and the use thereof as a heat conductor and/or heat exchanger.