Fiber Thermal Interface Pad for Conductivity and Compressibility
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Solution Overview
Problem
Current thermal interface materials (TIMs) for electric vehicle battery assemblies face challenges in achieving high thermal conductivity while maintaining low density and compressibility, often requiring high loading of inorganic fillers which compromise density and toughness.
Innovation Solution
The development of thermally conductive articles featuring entangled fibers with terminal ends on major surfaces and void spaces, impregnated with a polymer, which allows for continuous thermal pathways and low density through the use of less conductive material, enhancing thermal conductivity and compressibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high loading of inorganic fillers is used to achieve high thermal conductivity, then thermal conductivity is improved, but density increases and toughness deteriorates
Solution Approach 1:
The patent changes the physical state and morphology of thermally conductive materials from traditional particle form to fiber form. This parameter change allows fibers to align and entangle, creating continuous thermal pathways that achieve high thermal conductivity with lower material loading, thereby reducing density while maintaining thermal performance
Solution Approach 2:
The patent creates a composite structure combining thermally conductive fibers with a polymer matrix. This composite approach allows the fibers to provide thermal conductivity pathways while the polymer matrix maintains mechanical toughness and provides structural support, resolving the contradiction between thermal conductivity and toughness
2Temperature
If high loading of inorganic fillers is used to achieve high thermal conductivity, then thermal conductivity is improved, but toughness deteriorates
Solution Approach 1:
The patent transforms the morphology of thermally conductive materials from particles to fibers, changing the physical parameters of the composite. This fiber morphology enables entanglement and alignment that create continuous thermal pathways while maintaining material flexibility and toughness, unlike rigid particle fillers that compromise mechanical properties
Solution Approach 2:
The patent develops a composite material system where thermally conductive fibers are embedded in a polymer matrix. The fiber network provides thermal conductivity pathways while the polymer matrix contributes toughness and mechanical strength, achieving both high thermal conductivity and maintained toughness
3Temperature
If traditional TIM structures are used, then manufacturing is simple, but thermal conductivity and compressibility cannot be optimized simultaneously
Solution Approach 1:
The patent segments the thermally conductive material into individual fibers that can be randomly distributed in the polymer matrix. This segmentation allows each fiber to act as an independent thermal pathway, and the random distribution simplifies manufacturing processes while still achieving optimized thermal conductivity and compressibility through fiber entanglement and alignment
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
These articles achieve high thermal conductivity and compressibility with reduced material usage, providing effective thermal management and mechanical properties, addressing the limitations of traditional TIMs.
Implementation Method 1
the thickness is formed of a plurality of entangled thermally conductive fibers... providing effective thermal management
Implementation Method 2
The pad is at least partially impregnated with a polymer
Data Source
AI summary
The present disclosure provides a thermally conductive article including a pad having first and second opposed major surfaces and a thickness therebetween. The thickness is formed of entangled thermally conductive fibers and at least a portion of the entangled thermally conductive fibers have at least one terminal end at the first opposed major surface, the opposed second major surface, or both. The pad is at least partially impregnated with a polymer. Another thermally conductive article is provided including a) a pad having first and second opposed major surfaces and a thickness therebetween; b) a first thermally conductive skin layer; and c) a second thermally conductive skin layer. The thickness of the pad is formed of aligned thermally conductive fibers, and at least a portion of the thermally conductive fibers have a terminal end at the first opposed major surface and the opposed second major surface. The first and second thermally conductive skin layers each include a polymeric matrix at least partially embedded in the terminal end of at least a portion of the thermally conductive fibers at the first and second major surfaces of the pad, respectively. Methods of making the thermally conductive articles are also provided.