Creped Graphite Article Structure for Through-Thickness Heat Flow
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Solution Overview
Problem
Existing graphite articles are limited in their ability to effectively manage heat dissipation and thermal conductivity in three-dimensional applications, particularly in the direction perpendicular to the plane of the article, due to their anisotropic structure and lack of flexibility.
Innovation Solution
A creping process is applied to flexible graphite sheets to create three-dimensional articles with alternating convex and concave macrofolds and microfolds, enhancing their flexibility and thermal conductivity in the z-direction, while maintaining high thermal and electrical conductivity in the x-y plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a flat graphite sheet structure is used, then manufacturing simplicity is maintained, but thermal conductivity in the z-direction and flexibility are limited
Solution Approach 1:
The patent transforms the flat two-dimensional graphite sheet into a three-dimensional creped structure with alternating convex and concave regions. This dimensional change creates pathways for heat dissipation in the z-direction (through-thickness) while maintaining the inherent in-plane thermal conductivity, thereby resolving the contradiction between thermal conductivity and flat sheet structure.
Solution Approach 2:
The creping process introduces curvature to the graphite sheet by forming convex and concave regions with specific radii. This curvature enables the graphite to conform to non-planar surfaces and improves heat dissipation by creating multiple thermal pathways, addressing the limitation of flat sheet structures.
2Adaptability or versatility
If the graphite sheet is made more flexible through creping, then adaptability to 3D applications is improved, but structural complexity increases
Solution Approach 1:
By transitioning from a 2D flat sheet to a 3D creped structure, the graphite gains flexibility and adaptability to complex geometries. The creping process creates a controlled structural complexity that enables bending and conforming to surfaces while maintaining structural integrity, thus improving adaptability without excessive complexity.
Solution Approach 2:
The creped graphite sheet can be segmented into repeating units of convex and concave regions. This segmentation allows the material to be manufactured in a controlled manner while providing the flexibility needed for 3D applications. The modular nature of the creped structure enables adaptability without requiring complex monolithic designs.
3Temperature
If heat dissipation in the z-direction is enhanced through creping, then thermal management performance is improved, but manufacturing process complexity increases
Solution Approach 1:
The creping process creates a 3D structure from a 2D sheet, enabling heat dissipation in the z-direction. While this adds manufacturing steps, the process uses standard paper-making equipment (creping cylinder, doctor blade) to achieve the transformation, balancing improved thermal management with feasible manufacturing complexity.
Solution Approach 2:
The graphite sheet is creped during the manufacturing process before final application, pre-forming the heat-dissipating structure. This preliminary action ensures that the thermal management properties are built into the material itself, rather than requiring additional post-processing steps, thereby managing manufacturing complexity effectively.
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 creped graphite articles exhibit increased plasticity, thermal conductivity, and improved heat dissipation capabilities, allowing for better thermal management and adaptability in various applications, including thermal interfaces and laminates.
Implementation Method 1
A creping process is applied to flexible graphite sheets to create three-dimensional articles with alternating convex and concave macrofolds and microfolds
Implementation Method 2
enhancing their flexibility and thermal conductivity in the z-direction
Implementation Method 3
the dissipation of heat in the z direction (through the plane of the article) away from the heat source or the spreading of heat in x-y direction (within the plane of the article) away from a hot spot
Data Source
AI summary
A graphite article formed of a creped graphite sheet is provided. The creped graphite sheet has a first major surface and a second major surface oppositely disposed to the first major surface and a plurality of macrofolds, each macrofold having a plurality of associated microfolds, wherein each microfold is smaller than the associated macrofold. The creped graphite article has improved flexibility as compared to a graphite sheet which has not been creped. The creped graphite sheet can be formed of a sheet of flexible natural graphite or a sheet of synthetic graphite.