Heat Dissipation Sheet Filler Structure for High-Pressure Insulation
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Solution Overview
Problem
Heat dissipation sheets used in in-vehicle applications face challenges in maintaining high thermal conductivity and insulating properties under increased fastening pressures, leading to potential insulation failures and thermal resistance issues.
Innovation Solution
A heat dissipation sheet composed of 10-30% silicone resin and 70-90% thermally conductive filler, with controlled aspect ratios and particle orientations, is produced through specific mixing, preheating, and curing processes to ensure high dielectric breakdown voltage and low thermal resistance even at 1.0 MPa pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heat dissipation sheet with excellent heat dissipation performance is used, then heat dissipation capability is improved, but the sheet becomes brittle and prone to breaking during handling
Solution Approach 1:
The patent applies composite materials by combining a heat dissipation resin composition (containing heat dissipation fillers like boron nitride or aluminum oxide) with a flexible polymer matrix. This composite structure enables the sheet to simultaneously achieve excellent heat dissipation performance through the filler particles while maintaining mechanical strength and flexibility through the polymer matrix, directly resolving the contradiction between heat dissipation capability and brittleness
Solution Approach 2:
The patent employs parameter changes by carefully controlling the filler content within specific ranges (20-80 wt%), adjusting the resin-to-filler ratio, and modifying curing conditions. These parameter optimizations ensure that the heat dissipation resin composition achieves maximum heat dissipation capability while maintaining sufficient mechanical strength and flexibility to prevent breaking during handling
2Temperature
If high filler content is used to improve heat dissipation, then heat dissipation performance is improved, but manufacturing precision and uniformity deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-mixing the heat dissipation fillers with the resin material before molding. This preliminary mixing ensures uniform distribution of fillers throughout the resin matrix, preventing clustering or voids that would compromise sheet uniformity. The pre-formed resin composition maintains consistent properties throughout the molding process, enabling precise manufacturing even with high filler content
Solution Approach 2:
The patent controls manufacturing precision by optimizing parameters including filler particle size distribution, resin viscosity, and curing temperature. These parameter adjustments ensure that high filler content (20-80 wt%) does not compromise sheet uniformity, allowing the production of large-area sheets with consistent thickness and properties across the entire surface
3Ease of manufacture
If conventional molding methods are used, then manufacturing simplicity is maintained, but production time increases and productivity decreases
Solution Approach 1:
The patent applies preliminary action by pre-forming the heat dissipation resin composition into a sheet状 (sheet-form) structure before final assembly. This pre-formed sheet can be directly mounted onto heat-generating components without requiring complex in-situ molding processes, significantly reducing production time while maintaining manufacturing simplicity. The pre-formed sheet is ready for immediate installation, eliminating time-consuming molding steps
Solution Approach 2:
The patent applies segmentation by separating the heat dissipation resin composition into a distinct, pre-formed sheet component that can be independently manufactured and then assembled. This segmentation allows the heat dissipation sheet to be produced separately from the electronic component, enabling parallel production processes and reducing overall manufacturing cycle time while maintaining ease of assembly
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 sheet maintains excellent thermal conductivity and insulating properties under high pressure, preventing insulation failures and ensuring reliable operation in in-vehicle environments.
Implementation Method 1
a heat dissipation sheet comprising: a heat dissipation filler dispersed in a resin material
Implementation Method 2
a heat dissipation filler dispersed in a resin material
Data Source
Figure 1(a)~1(b)
Figure 2()a~2(b)
Figure 3(a)~3(b)
AI summary
Provided is a heat dissipation sheet containing a silicone resin and a thermally conductive filler, wherein, in a cross-sectional view in the thickness direction from one surface to the other surface of the heat radiation sheet, with respect to the cross-sectional shape of the thermally conductive filler, the average value of an aspect ratio of the 1st to 24th particles from the largest of biaxial average diameters, is in a range of 0.4 or more and 1.4 or less. As a result, it is possible to provide a heat dissipation sheet which exhibits excellent thermal conductivity and insulating property even under high pressure, and a method for producing the heat dissipation sheet. In addition, with respect to the 1st to 24th particles from the largest of biaxial average diameters, an area ratio (Sr) of a total area S of cross-sectional shapes of a plurality of the particles to a whole area of the cross-sectional view may be in a range of 20% or more and 80% or less, and the particle number ratio may be less than 1, preferably 0.4 or more and less than 1. Further, the heat dissipation sheet may have a thermal resistance ratio R0.4/R1.0 of 1 or more, wherein R0.4 is a thermal resistance value when a pressure of 0.4 MPa is applied in the thickness direction and R1.0 is a thermal resistance value when a pressure of 1.0 MPa is applied in the thickness direction.