Core/Shell Particles for Thermal Conductive 3D Printing
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Solution Overview
Problem
Current additive manufacturing techniques lack a simple method to produce electrically insulating and thermally conductive objects, which are crucial for preventing overheating in electronic devices.
Innovation Solution
A 3D printing process using a composite material with a polymer matrix and core/shell structured particles, where the core is thermally conductive and the shell is electrically insulating, providing high thermal conductivity without significant electrical conduction, and having a high form factor for improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional 3D printing materials are used, then the manufacturing process is simple, but the objects cannot achieve both thermal conduction and electrical insulation simultaneously
Solution Approach 1:
The patent uses composite particles with core/shell structure where the core provides thermal conduction and the shell provides electrical insulation. This composite structure allows simultaneous achievement of thermal conduction and electrical insulation properties in a single material system, resolving the contradiction between performance reliability and material complexity.
Solution Approach 2:
The particle structure is segmented into distinct functional zones: a thermally conductive core and an electrically insulating shell. This segmentation allows each component to independently perform its specific function, enabling the material to simultaneously achieve thermal conduction through the core while maintaining electrical insulation through the shell.
2Reliability
If high aspect ratio particles are used to improve thermal conduction, then thermal conductivity increases, but the charge rate increases and mechanical properties deteriorate
Solution Approach 1:
The patent optimizes the form factor parameter to be greater than 10, which balances thermal conduction efficiency with mechanical property maintenance. This parameter optimization ensures that the particles provide sufficient thermal conductivity while maintaining a reduced charge rate and acceptable mechanical properties in the printed object.
Solution Approach 2:
The core/shell structure provides local quality differentiation where the core region is optimized for thermal conduction while the shell region is optimized for electrical insulation and mechanical reinforcement. This local quality approach allows the particle to simultaneously achieve high thermal conductivity and maintain mechanical integrity.
3Temperature
If thermally conductive materials are used, then heat dissipation improves, but electrical conduction increases which is harmful for electronic devices
Solution Approach 1:
The electrically insulating shell acts as an intermediary layer between the thermally conductive core and the polymer matrix. This intermediary shell allows thermal energy to pass through the core while blocking electrical conduction, thus enabling heat dissipation without the harmful effect of electrical conduction in the composite material.
Solution Approach 2:
The particle structure exhibits local quality differentiation where the core provides thermal conduction and the shell provides electrical insulation. This allows the material to simultaneously achieve heat dissipation capability through the core while preventing electrical conduction through the shell, eliminating the harmful effect.
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 process enables the creation of printed objects with enhanced heat dissipation capabilities while maintaining electrical insulation, suitable for integration into electronic devices, with thermal conductivity greater than 2 W·m⁻¹·K⁻¹ and electrical resistivity exceeding 1×10¹³ ohm.cm.
Implementation Method 1
the core being made of a thermally conductive element... Thermally conductive means that the composite material has a thermal conductivity greater than 2 W·m-1
Implementation Method 2
the shell being made of an electrically insulating element... Electrically insulating means that the composite material has an electrical resistivity greater than 1×1013
Implementation Method 3
A 3D printing method comprising a step during which a composite material is melted then solidified
Implementation Method 4
A 3D printing method comprising a step during which a composite material is melted then solidified
Data Source
Figure 1
AI summary
The invention relates to a 3D printing method involving a step in which a composite material (100) is melted and then solidified, the composite material (100) comprising a polymer matrix (110) in which particles (120) with a core/shell structure are dispersed, the core (121) being made of a thermally conductive element and the shell (122) being made of an electrically insulating element, wherein the particles (120) have a form factor of greater than 10.