Heat-Conductive Sheet With Interface Filler Gradient
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Solution Overview
Problem
Heat-conducting sheets with exposed carbon fibers in laminated structures face issues such as poor adhesion between layers, bubble formation, and inadequate electrical insulation, limiting their application in electronic devices, while existing solutions with electrical insulation properties lack sufficient thermal conduction.
Innovation Solution
A heat-conducting sheet with a laminated structure featuring a lower anisotropic filler filling ratio in the interface between layers, combined with a higher non-anisotropic filler filling ratio, ensuring good adhesion and thermal conduction while maintaining electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat-conducting members with exposed carbon fibers are laminated to improve thermal conduction properties, then thermal conduction in the thickness direction is enhanced, but adhesion between layers deteriorates and bubbles form
Solution Approach 1:
The patent applies local quality by creating a skin layer with different properties from the bulk material. The skin layer has a lower filling ratio of anisotropic filler (carbon fibers) compared to the inner heat-conducting layers, which improves adhesion between laminated layers while the inner layers maintain high thermal conduction. This local differentiation resolves the contradiction between thermal conduction and adhesion.
2Reliability
If carbon fibers are oriented in the thickness direction to enhance thermal conduction, then thermal conduction properties improve, but electrical insulation properties deteriorate
Solution Approach 1:
The patent uses local quality by creating a skin layer with reduced anisotropic filler content at the surfaces. This skin layer provides electrical insulation while the inner layers with high anisotropic filler content provide thermal conduction. The differentiated structure allows simultaneous achievement of both thermal conduction and electrical insulation properties.
Solution Approach 2:
The patent employs composite materials by combining layers with different filler ratios and potentially different filler types. The skin layer may contain different filler materials or concentrations compared to the inner layers, creating a composite structure that achieves both thermal conduction and electrical insulation functions.
3Reliability
If a laminated structure is formed with heat-conducting layers to improve thermal conduction, then thermal conduction properties are enhanced, but manufacturing complexity increases due to adhesion issues
Solution Approach 1:
The patent simplifies manufacturing by creating a skin layer with lower anisotropic filler content that provides better adhesion properties. This local modification at the bonding surfaces facilitates the laminating process and reduces manufacturing complexity while maintaining the thermal conduction benefits of the laminated 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 solution achieves effective adhesion and thermal conduction in the thickness direction while securing electrical insulation, enhancing the sheet's versatility for electronic devices.
Implementation Method 1
a heat-conducting sheet used by arranging between a heat-generating element and a heat-dissipating element... to increase the efficiency of heat transfer... a filler having thermal conduction properties
Implementation Method 2
a polymer matrix having high flexibility, such as rubber or a gel
Data Source
AI summary
A heat-conducting sheet comprising a first heat-conducting layer, a second heat-conducting layer, an interface, a polymer matrix, an anisotropic filler and a non-anisotropic filler, wherein: the first and second heat-conducting layers each comprise the polymer matrix, the anisotropic filler and the non-anisotropic filler, the anisotropic filler oriented in a thickness direction, the first and second heat-conducting layers are laminated via the interface, the interface comprises the polymer matrix and the non-anisotropic filler, a filling ratio of the anisotropic filler in the interface is lower than that in the first and second heat-conducting layers, and a filling ratio of the non-anisotropic filler in the interface is higher than that in the first and second heat-conducting layers; and a method of producing the heat-conducting sheet.