Polymeric Sandwich Structure with Graphene Core for Thermal Conductivity
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Solution Overview
Problem
The existing methods for forming composite materials, such as prepregs, face challenges in heat propagation through the thickness of the material, requiring a significant amount of time for the heat from a heated mold to reach the opposite side, which hampers the efficiency of the molding process.
Innovation Solution
A polymeric sandwich structure is developed with a third layer containing graphene nanoplatelets and hollow microspheres, along with staggered discontinuous perforations in the fiber reinforcing sheets, which enhances thermal conductivity, allowing for faster heat propagation and reduced processing time by 20-50% compared to traditional methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional composite materials are used without thermal conductivity enhancement, then the material structure is simple and easy to manufacture, but the heat propagation time is excessive and processing efficiency is low
Solution Approach 1:
The patent applies composite materials by incorporating graphene nanoplatelets into the polymer matrix to create a thermally conductive core layer. This composite structure combines the thermal conductivity benefits of graphene with the structural properties of the polymer matrix, enabling faster heat propagation through the sandwich structure while maintaining manufacturability through established composite material processing techniques
Solution Approach 2:
The patent applies local quality by enhancing thermal conductivity only in the core layer where heat propagation is most needed, rather than throughout the entire structure. The core layer contains graphene nanoplatelets at concentrations of 0.1-5.0 wt%, creating a localized thermal management solution that accelerates heating without requiring modification of the entire composite structure
2Speed
If graphene nanoplatelets are added to enhance thermal conductivity, then heat propagation speed is improved, but the material complexity and manufacturing difficulty increase
Solution Approach 1:
The patent applies parameter changes by optimizing the graphene nanoplatelet concentration within a specific range (0.1-5.0 wt%) to achieve desired thermal conductivity improvements while avoiding excessive viscosity increases that would complicate manufacturing. This parameter optimization balances thermal performance with processability, allowing standard compression molding techniques to be used
Solution Approach 2:
The patent applies intermediary by using a polymer matrix as a medium to disperse and support the graphene nanoplatelets. The matrix acts as an intermediary that facilitates the integration of graphene into the composite structure, enabling straightforward processing through conventional polymer processing techniques while maintaining thermal conductivity enhancement
3Weight of moving object
If hollow microspheres are incorporated to reduce weight, then the density is reduced, but the structural strength may be compromised
Solution Approach 1:
The patent applies composite materials by combining hollow microspheres with the graphene-enhanced polymer matrix in the core layer. This composite approach creates a synergistic effect where the hollow microspheres provide weight reduction and the graphene nanoplatelets provide thermal conductivity and structural reinforcement, compensating for any strength loss from the hollow spheres
Solution Approach 2:
The patent applies local quality by concentrating hollow microspheres in the core layer where weight reduction is most beneficial, while the outer skin layers maintain higher structural integrity. This localized distribution optimizes the weight-strength balance by placing lightweight materials where they provide maximum benefit without compromising overall structural performance
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 polymeric sandwich structure enables faster heating of the polymer matrices, improving the flowability and moldability of composite parts, allowing for quicker and more efficient processing in compression molding.
Implementation Method 1
a third layer disposed between the first and second layers, wherein the third layer is formed from a third polymer matrix having graphene nanoplatelets interspersed therein... enabling each of the first, second and third polymer matrices to be heated... by continuous application of heat from the heated mold
Implementation Method 2
The third polymer matrix may include at least 50% by volume of hollow microspheres having an average diameter of about 10 to 100 microns
Data Source
AI summary
A polymeric sandwich structure having enhanced thermal conductivity includes a first layer formed from a first polymer matrix and including a first fiber reinforcing sheet embedded within the first polymer matrix, a second layer formed from a second polymer matrix and including a second fiber reinforcing sheet embedded within the second polymer matrix, and a third layer disposed between the first and second layers, the third layer formed from a third polymer matrix having graphene nanoplatelets interspersed therein. Each of the first and second fiber reinforcing sheets is made of reinforcing fibers and includes a respective set of staggered discontinuous perforations formed therein, wherein each respective set of staggered discontinuous perforations defines a respective first plurality of reinforcing fibers having a respective first length and a respective second plurality of reinforcing fibers having a respective second length longer than the respective first length.