Resin Sheet Thermal Conductor for Uneven Surface Integration
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Solution Overview
Problem
Conventional thermal conductors, such as graphite sheets, fail to effectively integrate with heat-generating parts and casings due to uneven surfaces, leading to partial contact and reduced heat conduction, causing high casing temperatures and potential damage from the required force for integration.
Innovation Solution
A resin sheet with a pressure-sensitive adhesive layer, featuring a resin foam with a 50% compression load of 20 N/cm² or less, a Poisson's ratio of 0.10 or less, and a thickness recovery ratio of 40% or more, allowing easy compression and recovery, is developed for efficient thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an inorganic material sheet having high thermal conductivity, such as a graphite sheet, is used as the thermal conductor, then the heat conduction capability is improved, but the temperature of part of the casing becomes extremely high causing discomfort or burn risk
Solution Approach 1:
The invention changes the material parameter from inorganic material to a specific resin composition with controlled thermal conductivity (0.3-3.0 W/m·K), which is lower than traditional graphite but provides more uniform heat distribution. This parameter change prevents extreme localized temperatures while maintaining effective heat removal through the casing.
2Reliability
If the thermal conductor is arranged in accordance with the small portion of the space, then the integration with heat-generating part is improved, but a gap occurs in the thick portion of the space making heat conduction difficult
Solution Approach 1:
The resin sheet possesses elastic properties that allow it to dynamically adapt to the uneven space between the heat-generating part and casing. When compressed, the resin deforms to fill gaps and conform to the contours, ensuring continuous contact across the entire surface area, thereby maintaining effective heat conduction throughout.
3Temperature
If the thermal conductor is arranged in accordance with the large portion of the space, then the heat conduction is improved, but the casing and heat-generating part cannot be integrated and fixed to each other in the thin portion of the space
Solution Approach 1:
The elastic nature of the resin sheet allows it to be compressed in thin portions without requiring excessive force, while still maintaining contact in large portions for effective heat conduction. The material dynamically adjusts its density and contact pressure distribution across the interface.
4Reliability
If a large force is applied for storing the inorganic material sheet having high thermal conductivity, such as a graphite sheet, in the thin portion of the space, then the integration is improved, but the casing that often includes a plastic or the like cannot resist a stress caused by the force and may break or crack
Solution Approach 1:
By changing from rigid inorganic materials to a compliant resin composition, the required compression force is dramatically reduced. The resin's elasticity allows it to conform to the space without requiring high forces that would damage plastic casings, while still achieving reliable thermal contact.
5Reliability
If the heat-generating part, the thermal conductor, and the casing are in contact with each other in an integrated manner, then the heat removal is improved, but the resin sheet must have specific compression and recovery properties to accommodate uneven surfaces
Solution Approach 1:
The invention uses a composite resin composition containing specific fillers (such as aluminum oxide, aluminum nitride, or boron nitride) dispersed in a resin matrix. This composite structure provides both the compliance needed for uneven surfaces and sufficient thermal conductivity for effective heat removal, balancing multiple property requirements.
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 resin sheet can be easily compressed and recovered, ensuring effective thermal conductivity between heat-generating parts and casings without causing damage, maintaining efficient heat removal and reducing casing temperatures.
Implementation Method 1
the resin sheet has a 50% compression load of 20 N/cm2 or less at 23±5° C. in a direction of the thickness 'd'
Implementation Method 2
the resin sheet has a thickness recovery ratio of 40% or more when compressed by 20% in the direction of the thickness 'd' at 23° C.
Implementation Method 3
Heat generated from the heat-generating part is conducted into the casing with the thermal conductor, and the heat is conducted from the casing to the outside, thereby cooling the heat-generating part
Data Source
AI summary
A resin sheet with a pressure-sensitive adhesive layer including the resin sheet. The resin sheet including a main surface A and a main surface B opposite to each other across a thickness “d”, where the resin sheet has a 50% compression load of 20 N/cm2 or less at 23±5° C. in a direction of the thickness “d”, which is measured in conformity with a method of measuring a compression hardness described in JIS K 6767:1999; where the resin sheet has a Poisson's ratio at 23° C. of 0.10 or less; and the resin sheet has a thickness recovery ratio of 40% or more when compressed by 20% in the direction of the thickness “d” at 23° C.