Heat Dissipation Sheet Manufacturing via Crosslinked Polymer Foam
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Solution Overview
Problem
Conventional heat dissipation sheets lack flexibility, are prone to cracking, and have limitations in heat dissipation performance due to high permittivity and low density, which can degrade the functionality of components and devices they are applied to, and also face challenges in adhering to uneven surfaces.
Innovation Solution
A method of manufacturing a heat dissipation sheet involving a preliminary sheet composed of a matrix-forming component, a crosslinking agent, and a heat dissipation filler, where the matrix-forming component is crosslinked using heat and pressure, and the sheet is cooled under controlled conditions to enhance flexibility and heat dissipation properties, with a high content of heat dissipation filler and specific particle size distribution for improved thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional heat dissipation materials with high heat dissipation performance are used, then heat dissipation performance is improved, but permittivity increases and resistance decreases, causing functional degradation of surrounding components
Solution Approach 1:
The patent changes the material parameters by using polymer foam structures with controlled cell sizes and wall thicknesses, achieving high heat dissipation performance through thermal conduction paths while maintaining low permittivity and appropriate resistance, thus avoiding functional degradation of surrounding components
Solution Approach 2:
The patent employs composite material structures combining polymer matrices with heat dissipation fillers or conductive networks within the foam structure, achieving simultaneous optimization of heat dissipation performance, electrical resistance, and permittivity properties
2Stability of the object's composition
If conventional heat dissipation sheets are made rigid for structural stability, then structural integrity is improved, but flexibility decreases, causing inability to adhere to uneven surfaces and risk of cracking
Solution Approach 1:
The patent employs flexible polymer foam sheet structures that can conform to uneven surfaces while maintaining structural integrity, using the foam's inherent flexibility to adapt to various geometries without cracking or delamination
Solution Approach 2:
The patent creates a dynamically adaptable heat dissipation sheet that can deform and conform to the underlying surface geometry, allowing the structure to adjust its shape while maintaining mechanical integrity and thermal performance
3Reliability
If heat dissipation filler content is increased to improve thermal conductivity, then heat dissipation performance is improved, but manufacturing processability deteriorates, reducing productivity
Solution Approach 1:
The patent utilizes porous foam structures that can accommodate high heat dissipation filler content within the cellular architecture, allowing efficient thermal conduction paths while maintaining ease of manufacturing through conventional foam forming processes
Solution Approach 2:
The patent segments the heat dissipation filler distribution within the foam structure, creating optimized thermal pathways through the cellular architecture that enhance thermal conductivity while facilitating straightforward manufacturing processes
4Ease of operation
If heat dissipation sheets are made thin for easy application, then ease of application is improved, but mechanical strength decreases, increasing susceptibility to cracking and damage
Solution Approach 1:
The patent employs thin flexible polymer foam sheets that maintain adequate mechanical strength through the foam's cellular structure, enabling easy application to surfaces while resisting cracking and damage during handling and installation
Solution Approach 2:
The patent uses composite foam structures with reinforced cellular walls or integrated strengthening agents that provide enhanced mechanical strength in thin sheet configurations, maintaining ease of application while preventing cracking
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 resulting heat dissipation sheet exhibits excellent heat dissipation performance, minimizes cracking and shrinkage, and achieves high productivity, making it suitable for mass production with enhanced flexibility and surface adhesion.
Implementation Method 1
crosslinking the matrix-forming component included in the preliminary sheet and thereby obtaining a heat dissipation sheet
Implementation Method 2
heat dissipation sheet having flexibility and excellent heat dissipation properties
Implementation Method 3
cooling the crosslinked preliminary sheets while applying pressure
Data Source
AI summary
A method of manufacturing a heat dissipation sheet including preparing a preliminary sheet including a matrix-forming component, a crosslinking agent, and a heat dissipation filler, and crosslinking the matrix-forming component included in the preliminary sheet and thus obtaining a heat dissipation sheet. The heat dissipation sheet manufactured has remarkably excellent heat dissipation properties because it contains a high content of heat dissipation filler. Due to the material properties of the matrix-forming component and the crosslinking of the matrix-forming component and the resulting matrix formation, the occurrence of cracking, shrinkage, pore formation, thickness change, and the like is minimized or prevented, and excellent flexibility can be attained. Moreover, since processability is improved through processes such as cooling when manufacturing the heat dissipation sheet, productivity is excellent, and the sheet can be suitable for mass production.