Composite Sheet Resolving Strength and Thermal Conductivity Trade-off

Solution Overview

Problem

Conventional composite materials with high thermal conductivity often have low yield strength, making them unsuitable for applications involving high compressive forces, especially at elevated temperatures, while materials with high yield strength are economically unfeasible for such demanding applications.

Innovation Solution

A three-dimensional composite sheet is created by patterning a high yield strength material and a high thermal conductivity material, where the high yield strength material primarily withstands compressive forces and the high thermal conductivity material primarily conducts heat, optimizing both properties in different dimensions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If high thermal conductivity materials like copper or aluminum are used, then heat conduction is improved, but yield strength decreases making them unable to withstand high compressive forces

Engineering Contradiction:

Improvethermal conductivityVSAvoidyield strength

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The composite sheet is segmented into distinct regions: a first region containing high yield strength material for structural support, and a second region containing high thermal conductivity material for heat conduction. This spatial segmentation allows each material to perform its optimal function without compromising the other property.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the composite sheet have different material compositions tailored to local functional requirements. The first region is optimized for mechanical strength to withstand compressive forces, while the second region is optimized for thermal conductivity to conduct heat away from the piston. This local quality differentiation resolves the contradiction between strength and thermal conductivity.

Inventive Principle:

Principle #3Local quality

2Strength

If high yield strength materials are used to withstand compressive forces, then strength is improved, but thermal conductivity decreases making them inadequate for heat conduction

Engineering Contradiction:

Improveyield strengthVSAvoidthermal conductivity

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The composite sheet is segmented into distinct regions: a first region containing high yield strength material for structural support, and a second region containing high thermal conductivity material for heat conduction. This spatial segmentation allows each material to perform its optimal function without compromising the other property.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the composite sheet have different material compositions tailored to local functional requirements. The first region is optimized for mechanical strength to withstand compressive forces, while the second region is optimized for thermal conductivity to conduct heat away from the piston. This local quality differentiation resolves the contradiction between strength and thermal conductivity.

Inventive Principle:

Principle #3Local quality

3Temperature

If exotic materials like Copper Tungsten are used to achieve both high thermal conductivity and high yield strength, then both properties are improved, but economic feasibility deteriorates

Engineering Contradiction:

Improvethermal conductivityVSAvoideconomic feasibility

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The invention uses a composite material structure combining two different materials (high yield strength material and high thermal conductivity material) in specific regions. This approach achieves the dual properties of high strength and high thermal conductivity through material combination rather than using expensive exotic materials like Copper Tungsten, thereby improving economic feasibility while maintaining performance.

Inventive Principle:

Principle #40Composite materials

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 sheet achieves higher compressive strength than the thermal conductivity material and higher thermal conductivity than the yield strength material, effectively withstanding forces and conducting heat efficiently, making it suitable for high-temperature applications like disk brake systems.

Implementation Method 1

the first material to primarily withstand the compressive force

Methodology Applied

Scientific EffectCompressive strength:

Implementation Method 2

the second material to primarily conduct the heat in the composite sheet

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS8304090B2High thermal conductivity, high yield strength metal composite and method

Publication Date: 2012.11.06 DEMERS JOSEPH R

AI summary

An exemplary embodiment providing one or more improvements includes a composite structure of materials that are formed together in a way which gives the composite structure improved yield strength and thermal conduction capabilities.