Core-Shell Composite Filler for Thermal Conduction and Electrical Insulation

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Solution Overview

Problem

Existing thermally conductive particles do not provide sufficient electrical insulation for electronic devices with increased voltage and current, necessitating a material with higher electrical insulation and thermal conduction properties.

Innovation Solution

A composite filler with a core-shell structure is developed, where the core is made of carbon, metal, zinc oxide, or zirconium oxide, and the shell is formed from fumed oxide particles attached through a dry ball mill process, resulting in a thermal conductivity of 0.075 W/m·K, volume resistivity of 1.0×105 Ω·cm, and dielectric breakdown voltage of 1 kV/mm.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional thermally conductive particles are used, then thermal conduction is achieved, but electrical insulation is insufficient for high voltage and current electronic devices

Engineering Contradiction:
Improveelectrical insulationVSAvoidcompatibility with high voltage and current electronic devices
Core Design Contradiction:
ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent applies composite materials by combining thermally conductive core particles (metal, ceramic, or carbon-based) with an insulating material coating to create a core-shell structure. This composite particle simultaneously provides thermal conduction through the core and electrical insulation through the coating, resolving the contradiction between thermal performance and electrical insulation for high voltage electronic devices.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by assigning different functional properties to different parts of the particle structure: the core provides thermal conduction while the shell provides electrical insulation. This spatial differentiation of functions allows the material to meet both thermal and electrical requirements simultaneously, enabling compatibility with high voltage and current electronic devices.

Inventive Principle:
Principle #3Local quality

2Reliability

If insulating material coating is applied to thermally conductive core particles, then electrical insulation is improved, but thermal conduction performance may be compromised

Engineering Contradiction:
Improveelectrical insulationVSAvoidthermal conduction
Core Design Contradiction:
ReliabilityVSTemperature

Solution Approach 1:

The patent applies parameter changes by carefully controlling the thickness and composition of the insulating coating layer. By optimizing these parameters, the coating provides sufficient electrical insulation while maintaining adequate thermal conduction performance, thus resolving the contradiction between electrical insulation and thermal conduction.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials with specific thermal and electrical properties for the coating layer. By selecting insulating materials with appropriate thermal conductivity and applying them in optimized thicknesses, the coating provides electrical insulation without significantly compromising thermal conduction 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 filler maintains high thermal conduction while achieving superior electrical insulation, enabling effective heat dissipation and reliability in electronic devices.

Implementation Method 1

the fumed oxide particles being attached to a part or a whole of the surface of the core substance by mixing of the fumed oxide particles and the core substance in a dry ball mill

Methodology Applied
Scientific EffectMechanical mixing and collision: Friction

Implementation Method 2

a thermal conductivity measured using a thermal conductivity measurement device 'TRIDENT' (manufactured by C-Therm Technologies Ltd.) and a compression test accessory (CTA) under a maximum compressive load condition (2400.0 gf) is equal to or more than 0.075 W/m·K

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

a volume resistivity measured using a high resistance resistivity meter 'Hiresta-UX' (manufactured by Mitsubishi Chemical Analytech Co., Ltd.: model number 'MCP-HT800') or a low resistance resistivity meter 'Loresta-GX' (manufactured by Mitsubishi Chemical Analytech Co., Ltd.: model number 'MCP-T700') and a powder resistance measurement system (manufactured by Mitsubishi Chemical Analytech Co., Ltd.: model number 'MCP-PD-51') is equal to or more than 1.0×105 Ω·cm

Methodology Applied
Scientific EffectElectrical resistance: Electrical Resistance

Data Source

PatentUS20260055312A1Composite filler and method for producing same
Publication Date: 2026.02.26 NIPPON AEROSIL CO LTD
  • US20260055312A1 patent drawing
  • US20260055312A1 patent drawing
  • US20260055312A1 patent drawing

AI summary

The composite filler filler forms a core-shell structure composed of a core substance made of carbon, metal, zinc oxide or zirconium oxide and a shell substance attached to a surface of the core substance. The shell substance is formed from fumed oxide particles, the fumed oxide particles being attached to a part or a whole of the surface of the core substance by mixing of the fumed oxide particles and the core substance in a dry ball mill. The fumed oxide particles are particles changed from bulky aggregated particles to gathered bulk particle. In the composite filler, percentage of the core substance ranges from 30 vol % to 85 vol % and percentage of the shell substance ranges from 15 vol % to 70 vol %, a thermal conductivity is 0.075 W/m·K or more, a volume resistivity is 1.0×105 Ω·cm or more, and a dielectric breakdown voltage is 1 kV/mm or more.