Copper Graphene Composite Heat Dissipation
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Solution Overview
Problem
Pyrolytic graphite sheets used for heat dissipation in smart devices are expensive, brittle, and prone to cracking, leading to high energy costs and material loss during manufacturing and handling.
Innovation Solution
A composite of copper foil with a graphene coating, which provides equivalent heat dissipation properties to pyrolytic graphite sheets but is more flexible, cost-effective, and easier to handle, with a surface roughness range of 0.5 to 2.5 μm for optimal adhesion and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If pyrolytic graphite sheets are used for heat dissipation, then heat dissipation performance is achieved, but manufacturing cost increases and material brittleness worsens
Solution Approach 1:
The patent uses composite materials by coating graphene onto copper foil substrates. This combination leverages the high thermal conductivity of both copper and graphene to achieve superior heat dissipation performance while maintaining flexibility and reducing manufacturing costs compared to pure pyrolytic graphite sheets.
Solution Approach 2:
The patent optimizes surface roughness parameters of the copper foil substrate (controlling it within 0.5-2.5 μm) to enhance graphene coating adhesion and heat dissipation efficiency. This parameter optimization allows achieving high heat dissipation performance with lower material costs and improved manufacturability.
2Temperature
If pyrolytic graphite sheets are used for heat dissipation, then heat dissipation performance is achieved, but material flexibility worsens and handling difficulty increases
Solution Approach 1:
By combining graphene coating with flexible copper foil substrate, the composite material maintains the high heat dissipation performance of graphite while gaining the flexibility and handling ease of metal foils. The copper foil provides mechanical strength and flexibility that pure graphite lacks.
Solution Approach 2:
The patent employs thin film technology by coating graphene as a thin layer on flexible copper foil. This approach creates a flexible heat dissipation component that can be easily handled, bent, and integrated into various device configurations without the brittleness of pure graphite sheets.
3Temperature
If pyrolytic graphite sheets are used for heat dissipation, then heat dissipation performance is achieved, but energy consumption increases due to high temperature processing
Solution Approach 1:
The copper foil substrate is prepared in advance with controlled surface roughness to optimize graphene coating adhesion. This preliminary preparation reduces the need for high-energy post-processing steps and minimizes energy consumption during the overall manufacturing process while maintaining heat dissipation performance.
Solution Approach 2:
The patent optimizes the surface roughness parameter of the copper foil to a specific range (0.5-2.5 μm) that maximizes graphene adhesion and heat dissipation efficiency. This optimized parameter reduces the energy required for coating processes and eliminates the need for high-temperature graphitization treatments, thereby reducing overall energy consumption.
4Temperature
If pyrolytic graphite sheets are used for heat dissipation, then heat dissipation performance is achieved, but material loss increases due to cracking and shattering
Solution Approach 1:
The composite structure of graphene-coated copper foil combines the heat dissipation benefits of graphite with the mechanical strength and crack resistance of copper. This prevents the cracking and shattering issues of pure graphite, reducing material loss during handling and installation.
Solution Approach 2:
The flexible copper foil substrate acts as a cushioning layer that prevents crack propagation in the graphene coating. This beforehand cushioning effect protects the heat dissipation layer from damage during handling and installation, minimizing material loss and waste.
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 copper-graphene composite offers effective heat dissipation, reduced manufacturing costs, increased flexibility, and recyclability, minimizing material loss and environmental impact.
Implementation Method 1
heat dissipative copper foil... heat dissipation properties... heat dissipation
Implementation Method 2
graphene/copper foil composite... heat dissipation properties equivalent to pyrolytic graphite sheets
Data Source
AI summary
A method of producing a composite heat dissipating structure by depositing a slurry of graphene particles upon a copper foil, drying the slurry to form a layer of graphene in contact with the copper foil, and consolidating the layer of graphene under pressure to reduce the thickness of the graphene layer and recovering the composite heat dissipating structure. Heat dissipating copper foils and composite heat dissipating structures and electronic devices incorporating the same are also disclosed herein.