Carbon Nanotube Thermal Interface Film With Exposed Tips
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Solution Overview
Problem
Existing thermal management materials using aligned carbon nanotubes in polymer matrices face challenges in achieving high thermal conductivity due to over-infiltration of polymer, which blocks access to the nanotube tips, limiting their effectiveness in thermal interface applications.
Innovation Solution
A thermal interface material comprising a sheet of aligned carbon nanotubes held in a partially cured polymer matrix, where the polymer is only infiltrated into the interstitial spaces between the nanotubes, leaving the tips exposed on both ends to ensure maximum thermal conductivity, and the material is processed to be substrate-free and flexible for efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polymer matrix material is infiltrated into the nanotube array, then the material gains structural support and adhesion, but thermal conductivity deteriorates when polymer covers the nanotube tips
Solution Approach 1:
The patent applies local quality by differentiating the polymer infiltration between different regions of the nanotube array. The polymer is allowed to infiltrate the interstitial spaces between nanotubes for structural support, but the nanotube tips are kept exposed to maintain thermal conductivity. This spatial differentiation of polymer presence optimizes both structural integrity and thermal performance.
Solution Approach 2:
The patent employs partial action by using only the necessary amount of polymer infiltration to provide structural support without excessive polymer that would coat the nanotube tips. The polymer is infiltrated partially into the interstitial spaces, just enough to hold the nanotube array together while leaving the tips accessible for thermal conduction.
2Stability of the object's composition
If polymer matrix material is used to hold nanotubes, then the material gains adhesion and structural integrity, but the nanotube tip accessibility is reduced
Solution Approach 1:
The patent applies local quality by differentiating the polymer infiltration between different regions of the nanotube array. The polymer is allowed to infiltrate the interstitial spaces between nanotubes for structural support, but the nanotube tips are kept exposed to maintain thermal conductivity. This spatial differentiation of polymer presence optimizes both structural integrity and thermal performance.
Solution Approach 2:
The patent employs partial action by using only the necessary amount of polymer infiltration to provide structural support without excessive polymer that would coat the nanotube tips. The polymer is infiltrated partially into the interstitial spaces, just enough to hold the nanotube array together while leaving the tips accessible for thermal conduction.
3Adaptability or versatility
If substrate-free flexible material is produced, then the material gains adaptability to conform to surfaces, but manufacturing complexity increases
Solution Approach 1:
The patent applies the extraction principle by removing the substrate from the final product. The nanotube array is grown on a substrate for manufacturing purposes, then the substrate is removed to create a free-standing, flexible thermal interface material. This extraction enables the material to conform to various surfaces while the manufacturing process retains controlled complexity through the use of removable substrates.
Solution Approach 2:
The patent creates a flexible thin film structure by producing a substrate-free nanotube array with polymer infiltration. The resulting material is a flexible sheet that can conform to different surface geometries, enabling adaptability while maintaining a relatively simple manufacturing process through controlled polymer infiltration and substrate removal.
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 enables enhanced thermal conductivity and improved thermal management by maintaining access to the nanotube tips, allowing for efficient heat transfer and adhesion, while being flexible enough to conform to surfaces, thus effectively addressing the limitations of previous materials.
Implementation Method 1
the polymer matrix material is only partially cured. The partially cured polymer matrix material may be selected from a group consisting of thermosetting resin, epoxy, vinyl ester, silicone, cyanate ester, bismaleimide (BMI), polyimide, polyolefin, polyurethane, phenolic, a carbonizable resin, polyfurfural and mixtures thereof
Implementation Method 2
Carbon nanotubes possess high electrical and thermal conductivities in the direction of the longitudinal axis of the carbon nanotubes. Individual carbon nanotubes have displayed thermal conductivities of 3000 W/m-° K. and higher at room temperature.
Data Source
AI summary
A flexible sheet of aligned carbon nanotubes includes an array of aligned nanotubes in a free standing film form not adhered to the synthesis substrate, with a matrix infiltrated interstitially into the nanotube array with access to the nanotube tips from both the top and bottom. That is, the infiltrant is purposely limited from over-filling or coating one or both exterior top and/or bottom surfaces of the array, blocking access to the tips. A typical matrix is a polymer material.