Oriented Graphite Thermal Sheet with Insulating Layer
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Solution Overview
Problem
Thermally conductive sheets with oriented scaly graphite particles face challenges in applications requiring both high thermal conductivity and insulating properties, as the addition of an insulating resin film reduces thermal conductivity and makes the sheet difficult to handle due to its hard surface.
Innovation Solution
A thermally conductive sheet is developed with an oriented-graphite layer and an insulating thermally conductive layer, where the oriented-graphite layer includes a polymer matrix with plate-like graphite powder oriented in the thickness direction, and the insulating layer includes a polymer matrix with an insulating thermally conductive filler, maintaining high thermal conductivity while providing insulating properties without significant reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an insulating resin film is stacked on a thermally conductive sheet filled with oriented scaly graphite particles, then insulating property is improved, but thermal conductivity is significantly reduced
Solution Approach 1:
The thermally conductive sheet is divided into multiple functional layers: a core layer with oriented scaly graphite particles for high thermal conductivity, and insulating resin film layers stacked on the surfaces for electrical insulation. This segmentation allows each layer to perform its specific function optimally without interfering with the thermal conduction pathway in the core layer.
Solution Approach 2:
The invention creates a composite structure combining thermally conductive graphite particles with insulating resin materials. The scaly graphite particles are embedded in a resin matrix, and additional insulating resin films are laminated on the surfaces, forming a multi-material composite that simultaneously achieves thermal conduction and electrical insulation properties.
2Object-affected harmful factors
If an insulating resin film is stacked on a thermally conductive sheet, then insulating property is improved, but ease of operation deteriorates due to hard surface
Solution Approach 1:
The insulating resin film is applied only on the surface layers of the thermally conductive sheet, providing electrical insulation where it is most needed for safety, while the core thermally conductive layer retains its original properties for heat transfer. This localized application of insulating material minimizes the impact on overall handling characteristics.
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 achieves high thermal conductivity and insulating properties, making it suitable for various applications and easy to handle due to its adapted hardness and thickness, ensuring effective heat transfer and adhesion.
Implementation Method 1
the oriented-graphite thermally conductive layer including a polymer matrix including a plate-like graphite powder, flat surfaces of particles of the plate-like graphite powder being oriented in the thickness direction of the sheet
Implementation Method 2
the insulating thermally conductive layer including a polymer matrix including an insulating thermally conductive filler dispersed in the polymer matrix, the insulating thermally conductive layer having a thermal conductivity and an insulating property
Data Source
AI summary
Provided is a thermally conductive sheet including an oriented-graphite thermally conductive layer and an insulating thermally conductive layer stacked on the oriented-graphite thermally conductive layer, the oriented-graphite thermally conductive layer including a polymer matrix including a plate-like graphite powder, flat surfaces of particles of the plate-like graphite powder being oriented in the thickness direction of the sheet, the insulating thermally conductive layer including a polymer matrix including an insulating thermally conductive filler dispersed in the polymer matrix, the insulating thermally conductive layer having a thermal conductivity and an insulating property. The thermally conductive sheet has a high thermal conductivity and an insulating property, is capable of being readily fixed to an adherend, and is easy to handle.