Thermal Interface Material with Aligned Carbon Nanotubes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional thermal interface materials have a low heat conduction coefficient, which is insufficient for modern electronic components, and existing materials with carbon nanotubes are either too thick, reducing flexibility and uniform heat distribution.
Innovation Solution
A thermal interface material with a matrix and aligned carbon nanotubes, where the nanotubes extend from one surface to the other with phase change layers on their ends, enhancing heat conduction efficiency and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon fibers are used to create a thermal interface material with high heat conduction coefficient, then heat conduction coefficient is improved, but thickness cannot be reduced below 40 micrometers which limits further improvement
Solution Approach 1:
The patent changes the fundamental thermal conduction mechanism from relying on thick carbon fiber mats to using thin carbon nanotube layers with phase change materials. This parameter change in material structure and thermal conduction approach enables achieving high heat conduction coefficients at much thinner dimensions (below 40 micrometers), directly resolving the contradiction between heat conduction performance and thickness limitation.
Solution Approach 2:
The patent creates a composite material system combining carbon nanotubes with phase change materials (such as paraffin or fatty acids). This composite structure leverages the high thermal conductivity of carbon nanotubes for heat spreading and the phase change materials for heat absorption and uniform distribution, achieving superior thermal performance at reduced thickness compared to conventional carbon fiber-based materials.
2Ease of manufacture
If injection molding is used to form thermal interface material with carbon nanotubes, then material can be formed, but the material becomes relatively thick which reduces flexibility and uniform heat distribution
Solution Approach 1:
The patent changes the manufacturing approach from injection molding (which produces thick parts) to lamination or transfer printing methods that can produce thin-film structures. This process parameter change enables achieving uniform, thin thermal interface materials with excellent flexibility while maintaining ease of manufacture through standardized thin-film production techniques.
3Ease of manufacture
If carbon nanotubes are disposed randomly in matrix material, then material can be formed, but heat does not spread uniformly through the thermal interface material
Solution Approach 1:
The patent applies preliminary action by pre-aligning carbon nanotubes in a specific orientation (parallel to each other and perpendicular to the substrate surface) before incorporating them into the phase change material matrix. This preliminary arrangement ensures that heat spreads uniformly through the thermal interface material, as the aligned nanotubes create consistent thermal pathways, while still allowing for practical manufacturing through techniques like vertical field emission display (VFED) processes.
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 provides a high heat conduction coefficient with reduced thermal interface resistance, ensuring efficient heat transfer and flexibility, even on uneven surfaces.
Implementation Method 1
Each carbon nanotube extends from the first surface to the second surface... A heat conduction coefficient of this kind of thermal interface material is relatively high
Implementation Method 2
The at least one phase change layer is formed on the exposed end of the carbon nanotubes
Data Source
AI summary
A thermal interface material includes a matrix, a plurality of carbon nanotubes, and at least one phase change layer. The matrix includes a first surface and an opposite second surface. The carbon nanotubes are embedded in the matrix uniformly. The carbon nanotubes extend from the first surface to the second surface and have two opposite ends. At least one of the two opposite ends of the carbon nanotubes is exposed out of one of the first and second surfaces of the matrix. The at least one phase change layer is formed on the exposed end of the carbon nanotubes.