Quasi-spherical thermal gap pad suppresses oil bleeding
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Solution Overview
Problem
Current thermal gap pad materials suffer from oil bleeding, which leads to pollution, operational issues, and potential short circuits, while attempts to reduce oil bleeding often compromise thermal conductivity and mechanical properties.
Innovation Solution
A thermal gap pad material comprising a matrix of silicone resin and quasi-spherical thermally conductive fillers with a specific degree of sphericity and surface area, which effectively adsorbs grease without increasing mixture viscosity, maintaining high thermal conductivity and mechanical flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the surface area of thermally conductive fillers is increased to adsorb more grease and suppress oil bleeding, then oil bleeding is reduced, but the viscosity of the mixture increases greatly, leading to difficulties in operation
Solution Approach 1:
The patent changes the parameters of the fillers by controlling their particle size distribution (D10-D90 ratio of 0.05-0.5) and surface area (0.1-10 m²/g) to achieve effective grease adsorption while maintaining manageable mixture viscosity. This parameter optimization allows the material to suppress oil bleeding without becoming excessively viscous during preparation and application.
Solution Approach 2:
The patent creates a composite material system combining silicone resin with specifically engineered thermally conductive fillers (alumina, aluminum hydroxide, silicon carbide, or boron nitride) that have controlled particle size distribution and surface area. This composite structure enables effective grease adsorption while maintaining operational ease through balanced material properties.
2Object-generated harmful factors
If the particle size of fillers is reduced to increase specific surface area and reduce oil bleeding rate, then oil bleeding is suppressed, but the packing density of fillers increases, resulting in a drastic decrease in compressibility
Solution Approach 1:
The patent optimizes the particle size parameters by controlling the D10-D90 ratio within 0.05-0.5 and specific surface area within 0.1-10 m²/g. This parameter control achieves sufficient grease adsorption capacity while preventing excessive packing density that would compromise compressibility. The balanced particle size distribution ensures both oil bleeding suppression and mechanical flexibility.
3Object-generated harmful factors
If a surface treatment layer is added to suppress silicone oil bleeding, then oil bleeding is reduced, but thermal conductivity is lowered
Solution Approach 1:
The patent extracts the oil bleeding suppression function from a separate surface treatment layer and integrates it into the bulk material through the use of thermally conductive fillers with controlled surface area and particle size distribution. This approach eliminates the need for additional surface treatment layers that would compromise thermal conductivity, as the grease adsorption capability is built into the filler characteristics themselves.
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 prevents oil bleeding while ensuring high thermal conductivity and mechanical properties like flexibility and compressibility, making it suitable for various electronic applications.
Implementation Method 1
the thermally conductive filler has particles which are approximately spherical in shape... an average degree of sphericity of 70%-90%... effectively adsorbs grease
Data Source
AI summary
The present disclosure relates to new types of low oil bleeding thermal interface materials, such as thermal gap pad materials, which may be in the form of a thermally conductive gasket. In exemplary embodiments, a thermal interface material comprises a matrix material and a thermally conductive filler. The thermally conductive filler has particles which are approximately spherical in shape when observed using a scanning electron microscope, an average particle diameter (D50) of 2-120 μm, and an average degree of sphericity of 70-90%. According to the present disclosure, by using a quasi-spherical thermally conductive filler having a specific sphericity, oil bleeding can be prevented, mitigated, or reduced while achieving high thermal conductivity compared to the case of using a perfectly spherical or irregularly shaped thermally conductive filler.