Thermally Conductive Sheet Surface Resin Coating for Insulation
Solution Overview
Problem
Thermally conductive sheets with both high thermal conductivity and electrical insulation are challenging to achieve due to the anisotropy of thermal conductivity in fillers like carbon fibers, which can cause short circuits when exposed and degrade thermal conductivity when buried for insulation.
Innovation Solution
A thermally conductive sheet with a cured binder resin and carbon fibers covered by insulating coating films, where the carbon fibers on the surface are not covered by the films but instead by the binder resin, maintaining thermal conductivity while ensuring electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If carbon fibers are used as thermally conductive fillers to achieve high thermal conductivity, then thermal conductivity is improved, but electrical conductivity increases causing short circuit risks
Solution Approach 1:
The patent applies local quality by differentiating the treatment of carbon fibers in different locations: internal carbon fibers are coated with insulating films for electrical isolation, while surface-exposed carbon fibers remain uncovered to maintain thermal conductivity. This spatial differentiation resolves the contradiction between electrical insulation and thermal conductivity.
Solution Approach 2:
The patent segments the carbon fiber population into two groups based on location: buried carbon fibers within the sheet body that require insulating coating, and exposed carbon fibers on the surface that should remain uncovered. This segmentation allows simultaneous optimization of both electrical insulation and thermal conductivity properties.
2Reliability
If carbon fibers are buried in the sheet body to ensure electrical insulation, then electrical insulation is improved, but thermal conductivity is degraded
Solution Approach 1:
The patent applies local quality by differentiating the treatment of carbon fibers in different locations: internal carbon fibers are coated with insulating films for electrical isolation, while surface-exposed carbon fibers remain uncovered to maintain thermal conductivity. This spatial differentiation resolves the contradiction between electrical insulation and thermal conductivity.
3Reliability
If insulating coating films are applied to carbon fibers to prevent short circuits, then electrical insulation is improved, but thermal conductivity is reduced
Solution Approach 1:
The patent applies local quality by differentiating the treatment of carbon fibers in different locations: internal carbon fibers are coated with insulating films for electrical isolation, while surface-exposed carbon fibers remain uncovered to maintain thermal conductivity. This spatial differentiation resolves the contradiction between electrical insulation and thermal conductivity.
Solution Approach 2:
The patent applies partial action by selectively coating only the carbon fibers that are buried within the sheet body with insulating films, while leaving the surface-exposed carbon fibers uncovered. This partial application of insulating coating minimizes the impact on thermal conductivity while sufficient to prevent short circuits.
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 effectively suppresses thermal conductivity reduction and achieves both insulating and thermal conductivity properties, preventing short circuits and maintaining high thermal performance.
Implementation Method 1
a sheet body that is a cured product of a thermally conductive resin composition including a binder resin and carbon fibers covered with insulating coating films, wherein the carbon fibers exposed on a surface of the sheet body are not covered with the insulating coating films and are covered with a component of the binder resin
Data Source
AI summary
A thermally conductive sheet including a sheet body that is a cured product of a thermally conductive resin composition including a binder resin and carbon fibers covered with insulating coating films, wherein the carbon fibers exposed on a surface of the sheet body are not covered with the insulating coating films and are covered with a component of the binder resin.