Thermal Paste Composition Using Metal Powder for Uniform Heat Transfer
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Solution Overview
Problem
Current thermal pastes, including liquid metal variants, face limitations in thermal conduction capability and uniform coating, while being expensive and difficult to apply uniformly, and silicone resin-based pastes lack sufficient thermal conductivity.
Innovation Solution
A manufacturing method involving the use of low-melting point metal powders, such as gallium indium tin alloys, mixed with a silicone-based base material, utilizing sieving and dispersants to ensure uniform distribution and improved thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid metal material is used to improve thermal conduction capability, then thermal conduction capability is improved, but cost increases and coating uniformity deteriorates
Solution Approach 1:
The liquid metal material is segmented into powder form through freezing and crushing processes. This segmentation transforms the continuous liquid metal into discrete particles that can be uniformly distributed in the thermal paste, solving the coating uniformity issue while maintaining thermal conduction capability.
Solution Approach 2:
The physical state of the metal material is changed from liquid to solid powder through controlled freezing. This parameter change enables the metal to be processed into a form suitable for uniform mixing and coating, while the thermal conduction properties are preserved in the powder form.
2Reliability
If liquid metal material is used to improve thermal conduction capability, then thermal conduction capability is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses a small amount of liquid metal material in powder form dispersed in a silicone resin base. This approach uses minimal quantities of the expensive metal material while achieving improved thermal conduction, making the overall product more cost-effective compared to pure liquid metal thermal paste.
Solution Approach 2:
The patent creates a composite thermal paste by combining metal powder particles with silicone resin base material. This composite structure leverages the high thermal conduction of metal particles while using the inexpensive silicone resin as the continuous phase, reducing overall manufacturing cost while maintaining thermal performance.
3Object-affected harmful factors
If silicone resin base material is used, then insulation performance is ensured, but thermal conduction capability deteriorates
Solution Approach 1:
The patent creates a composite structure where silicone resin provides the insulating matrix while dispersed metal powder particles provide thermal conduction pathways. This composite approach allows simultaneous achievement of electrical insulation from the resin and thermal conduction from the metal particles.
Solution Approach 2:
The thermal conduction property is localized to the metal powder particles dispersed within the silicone resin. The resin provides insulation in the bulk, while the metal particles create localized high-conduction pathways at the interface between heat source and heat sink, achieving both insulation and thermal conduction 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 method enhances thermal conductivity and facilitates uniform application of thermal paste, maintaining insulation properties, thus improving heat dissipation efficiency and ease of application.
Implementation Method 1
heating a metal material to a liquid state, to generate a liquid metal material
Implementation Method 2
A phase change endothermic characteristic of the liquid metal is used to improve heat dissipation efficiency thereof
Data Source
AI summary
A manufacturing method of thermal paste is provided. The manufacturing method includes: providing a base material; heating a metal material to a liquid state, to generate a liquid metal material; sieving the liquid metal material to generate a metal powder material; adding a dispersant to the metal powder material and mixing to generate a mixed powder material; and mixing the mixed powder material and the base material.