Particle-Packed Insulating Sheet for In-Plane Heat Diffusion
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Solution Overview
Problem
Conventional insulation sheets fail to achieve sufficiently high thermal conductivity in the in-plane direction, which is essential for effectively dissipating heat from heat-generating components in electronic devices.
Innovation Solution
The insulation sheet is composed of 75 to 97% insulating particles, 3 to 25% binder resin, and 10% or less voids, with a high packing ratio of insulating particles achieved through a roll press treatment, enhancing thermal conductivity while maintaining electrical insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the content of insulating particles is increased to improve thermal conductivity, then the thermal conductivity in the in-plane direction is improved, but the sheet becomes difficult to manufacture and maintain structural integrity
Solution Approach 1:
The patent optimizes the quantitative composition parameters of the sheet, specifically setting insulating particles at 75-97% by area, binder resin at 3-25% by area, and voids at 10% by area or less. This parameter optimization achieves high thermal conductivity while maintaining manufacturability and structural integrity
Solution Approach 2:
The patent creates a composite material system combining insulating particles (such as boron nitride) with binder resin in specific proportions. This composite structure enables the sheet to achieve high thermal conductivity through the particle network while the binder resin provides structural cohesion and manufacturability
2Temperature
If the content of insulating particles is increased to improve thermal conductivity, then the thermal conductivity in the in-plane direction is improved, but the structural integrity and flexibility of the sheet deteriorate
Solution Approach 1:
The patent optimizes the quantitative composition parameters, specifically setting insulating particles at 75-97% by area and binder resin at 3-25% by area. This optimization achieves high thermal conductivity while maintaining sufficient structural integrity and flexibility
Solution Approach 2:
The patent creates a composite material system where insulating particles form a thermal conduction network while binder resin provides structural cohesion. This composite structure enables the sheet to achieve high thermal conductivity through the particle network while the binder resin maintains structural integrity and flexibility
3Temperature
If voids are reduced to improve thermal conductivity, then the thermal conductivity in the in-plane direction is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent optimizes the void content parameter to 10% by area or less through composition design and processing condition optimization. This achieves high thermal conductivity while controlling manufacturing process complexity through systematic parameter management
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
This configuration results in a sheet with high thermal conductivity in the in-plane direction, effectively diffusing heat away from heat sources, reducing local temperature rises, and preventing electrical leakage, while maintaining electrical insulation.
Implementation Method 1
a thermal conductive member capable of heat conduction in a specific direction is required
Implementation Method 2
for the purpose of preventing an electrical leakage to the coolant or housing, the thermal conductive member is also required to have electrical insulation properties
Data Source
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AI summary
An object of the present invention is to provide an insulation sheet having high thermal conductivity in the in-plane direction. The present invention provides an insulation sheet comprising insulating particles and a binder resin, wherein, for the entire cross-section of the sheet perpendicular to the in-plane direction, the insulation sheet contains 75 to 97 % by area of the insulating particles, 3 to 25 % by area of the binder resin, and 10 % by area or less of the voids.