Foamed Skeleton Composite for High Thermal Conductivity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current composite materials with diamond particles exhibit low thermal conductivity due to isolated heat-conducting islands and high contact thermal resistance, making it difficult to achieve synergistic effects and fully utilize the thermal conductivity of diamond, especially in electronic packaging materials as frequency and power increase.
Innovation Solution
A foamed skeleton reinforced composite material is developed using chemical vapor deposition (CVD) to construct a highly thermal conductivity channel, combining a foamed skeleton with a matrix material, where the foamed skeleton is made from metals, inorganics, or organics, and the reinforcing layer includes diamond, graphene, or carbon nanotubes, forming a continuous interpenetrating structure to enhance thermal conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If diamond particles are added to metal matrix to improve thermal conductivity, then thermal conductivity is enhanced, but the particles form isolated heat-conducting islands with high contact thermal resistance, limiting synergistic effects
Solution Approach 1:
The patent embeds diamond particles within carbon nanotube networks and graphene layers, creating a nested structure where multiple thermal conduction pathways are integrated. The diamond particles are nested within the carbon nanotube forest, which is in turn nested within the graphene matrix, forming concentric thermal conduction channels that reduce contact thermal resistance.
Solution Approach 2:
The patent creates a multi-phase composite structure combining diamond particles, carbon nanotubes, and graphene in a metal matrix. This composite approach leverages the complementary thermal conductivity properties of each material phase to overcome the limitations of single-phase composites and reduce interfacial thermal resistance.
2Temperature
If filling amount of thermal conductive particles is increased to form effective thermal conducting network, then thermal conductivity improves, but the final thermal conductivity remains much lower than pure conductive material due to high contact thermal resistance
Solution Approach 1:
The patent introduces carbon nanotubes and graphene as intermediary materials between diamond particles and the metal matrix. These intermediaries provide continuous thermal conduction pathways that bridge the diamond particles, reducing the need for high filling amounts and lowering contact thermal resistance at interfaces.
Solution Approach 2:
The patent creates localized regions of high thermal conductivity by concentrating diamond particles within carbon nanotube networks and graphene layers. This local quality enhancement allows effective thermal conduction in specific regions without requiring uniform high filling throughout the entire matrix, thereby reducing overall contact thermal resistance.
3Shape
If conventional machining or metal wire weaving is used to prepare three-dimensional porous skeleton, then skeleton structure is obtained, but the process is complex with many steps and high cost, and it is difficult to control internal aperture and connectivity
Solution Approach 1:
The patent replaces conventional mechanical machining and metal wire weaving processes with chemical vapor deposition (CVD) methods. This substitution eliminates complex mechanical processing steps and enables precise control of pore structure through chemical reaction parameters, significantly simplifying the manufacturing process.
Solution Approach 2:
The patent controls the internal aperture and connectivity of the three-dimensional porous skeleton by adjusting CVD process parameters such as temperature, pressure, gas flow rates, and deposition time. This parameter-based control replaces the trial-and-error approach of mechanical processing and enables precise tailoring of pore structure.
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 method significantly improves thermal conductivity efficiency, maintaining the plasticity and toughness of the matrix while maximizing the thermal conductivity of the reinforcing phase, achieving thermal conductivities up to 976 W/(m·K in metal matrix composites and 567 W/(m·K in polymer matrix composites, surpassing traditional composites in thermal, electrical, and mechanical properties.
Implementation Method 1
chemical vapor deposition (CVD) to construct a highly thermal conductivity channel
Implementation Method 2
diamond has highly thermal conductivity (up to 2200 W/(m·K) at room temperature)
Data Source
AI summary
A foamed skeleton reinforced composite, comprising a foamed skeleton and a matrix material. The foamed skeleton is selected from at least one of a metal foamed skeleton, an inorganic non-metal foamed skeleton, and an organic foamed skeleton. The matrix material is selected from a metal or a polymer.