Resin-Diamagnetic Composite for Heat Dissipation and Insulation

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Solution Overview

Problem

Conventional resin-diamagnetic material composites face issues with adhesion between the resin sheet and thermally conductive members, leading to unsatisfactory heat dissipation characteristics and electrical insulation properties, particularly when thermally conductive materials like graphite are exposed, compromising the integrity and insulation of the composite structure.

Innovation Solution

A composite structure is developed by incorporating a diamagnetic material layer, such as graphite or bismuth, and a resin layer, where the diamagnetic material is aggregated and covered with a resin sheet, utilizing a magnetic field to enhance adhesion and ensure proper bonding between the layers, thereby improving thermal conductivity and electrical insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a resin layer is disposed on the surface of a substrate to ensure insulation properties, then electrical insulation is improved, but heat dissipation characteristics deteriorate

Engineering Contradiction:

Improveelectrical insulationVSAvoidheat dissipation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent uses a composite structure combining resin (for insulation) and graphite particles (for thermal conductivity). The resin matrix provides electrical insulation while the dispersed graphite particles create thermal conduction paths, achieving both insulation and heat dissipation simultaneously.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent creates local thermal conduction paths within the resin by dispersing graphite particles strategically. The resin maintains its insulating property throughout while graphite clusters form localized high-conductivity regions that facilitate heat dissipation without compromising overall insulation.

Inventive Principle:

Principle #3Local quality

2Temperature

If a metal plate is used as a radiating plate, then heat dissipation is improved, but electrical continuity is generated causing adverse influence on power element operation

Engineering Contradiction:

Improveheat dissipationVSAvoidelectrical insulation

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent replaces pure metal with a composite material consisting of resin and graphite particles. This composite provides thermal conductivity comparable to metal while the resin matrix ensures electrical insulation, eliminating the electrical continuity problem inherent in metal plates.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The resin acts as an intermediary material that decouples the thermal and electrical properties. It allows heat to be conducted through graphite particles while preventing electrical conduction, serving as a mediating substance between the power element and the radiating plate function.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If small pieces of graphite sheet are mixed in insulating sheet, then thermal conductivity is improved, but adhesion between layers deteriorates

Engineering Contradiction:

Improvethermal conductivityVSAvoidadhesion

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The patent modifies the physical and chemical parameters of the resin matrix, including its viscosity, curing characteristics, and surface properties, to optimize adhesion to graphite particles. By adjusting resin composition and curing conditions, the patent achieves strong interfacial bonding while maintaining the thermal conductivity benefits of graphite dispersion.

Inventive Principle:

Principle #35Parameter changes

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 composite structure achieves enhanced thermal conductivity and electrical insulation, ensuring effective heat dissipation and reduced electromagnetic noise, while maintaining structural integrity and preventing electrical continuity issues.

Implementation Method 1

a diamagnetic material layer (12), and a resin layer (14) that covers at least a part of a surface of the diamagnetic material layer (12)... the diamagnetic material layer (12) is a layer formed by aggregation of particles of a diamagnetic material

Methodology Applied

Scientific EffectDiamagnetism: Diamagnetism

Implementation Method 2

a resin layer (14) that covers at least a part of a surface of the diamagnetic material layer (12)... ensuring electrical insulation properties

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 3

enhanced thermal conductivity and electrical insulation, ensuring effective heat dissipation

Methodology Applied

Scientific EffectThermal conductivity: Conduction (thermal)

Data Source

PatentUS8704362B2Resin-diamagnetic material composite structure

Publication Date: 2014.04.22 PANASONIC HOLDINGS CORP

AI summary

A composite structure 10 of a resin-diamagnetic material, including a diamagnetic material layer 12 and a resin layer 14 is obtained by a method including disposing particles of a diamagnetic material 22 and a resin 24 in a mold 30, applying a magnetic field to the diamagnetic material 22 disposed in the mold 30, and moving the diamagnetic material 22 in a direction away from at least a part of an inner surface of the mold 30, and then curing the resin 24 in the mold 30 thereby to produce a resin-diamagnetic material composite structure.