Unitary Graphene Matrix Composite for Thermal Management
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Solution Overview
Problem
Existing graphitic materials for heat dissipation, such as flexible graphite foils and carbon nano-tube papers, suffer from low thermal conductivity, mechanical weakness, and a tendency to flake off, leading to internal shorting and structural integrity issues in electronic devices.
Innovation Solution
A graphene oxide gel-derived unitary graphene matrix composite with closely packed, chemically bonded graphene planes and a carbon or graphite filler phase, which is produced through a process that aligns and merges graphene oxide molecules into a single crystal or poly-crystal structure with all planes parallel, eliminating discrete flakes and enhancing thermal and electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If flexible graphite foils and carbon nano-tube papers are used for heat dissipation, then the material can be formed into flexible structures, but the thermal conductivity is low and mechanical strength is weak
Solution Approach 1:
The patent combines unitary graphene matrix material with carbon or graphite filler particles to create a composite material that achieves both high thermal conductivity (>1,700 W/mK) and high mechanical strength. The graphene matrix provides thermal conductivity while the filler particles reinforce mechanical properties, resolving the contradiction between thermal performance and mechanical strength.
Solution Approach 2:
The patent changes the structural parameters of graphite materials by creating a unitary graphene matrix with closely packed, chemically bonded graphene planes and parallel orientations. This structural transformation from random flake arrangements to ordered parallel structures dramatically increases thermal conductivity while maintaining mechanical integrity.
2Reliability
If conventional graphite materials are used, then the material can be formed into bulk structures, but graphite flakes tend to flake off causing internal shorting and structural integrity issues
Solution Approach 1:
The patent extracts and eliminates discrete graphite flakes from the material structure by forming a continuous unitary graphene matrix. The matrix material contains no discrete flakes, preventing flake detachment and internal shorting while maintaining structural integrity and reliability.
Solution Approach 2:
The patent merges individual graphene planes into a unified, continuous matrix structure through chemical bonding. This merging eliminates boundaries between discrete flakes, creating a monolithic structure that prevents flake detachment and ensures structural integrity.
3Temperature
If natural graphite particles are used, then the material is readily available, but the graphene planes have random orientations resulting in average properties and low thermal conductivity
Solution Approach 1:
The patent changes the orientation parameter of graphene planes from random to parallel alignment. By controlling the formation process to create closely packed, chemically bonded graphene planes with parallel orientations, the material achieves high thermal conductivity while maintaining compositional stability.
Solution Approach 2:
The patent creates local parallel orientation of graphene planes throughout the matrix structure. Each region of the unitary graphene matrix exhibits consistent parallel orientation of graphene planes, ensuring uniform high thermal conductivity properties throughout the entire material.
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 achieves exceptional thermal conductivity exceeding 1,700 W/mK, high electrical conductivity, mechanical strength, and scratch resistance, while preventing graphite flakes from flaking off, thus addressing the limitations of prior materials in thermal management applications.
Implementation Method 1
heat-treating a graphene oxide gel at a temperature higher than 100° C.
Implementation Method 2
closely packed and chemically bonded graphene planes
Implementation Method 3
the graphene planes are stacked and bonded via van der Waal forces in the crystallographic c-direction
Data Source
AI summary
A unitary graphene matrix composite comprising: (a) a unitary graphene matrix containing an oxygen content of 0.001% to 10% by weight, obtained from heat-treating a graphene oxide gel at a temperature higher than 100° C. and contains no discrete graphene platelets derived from the graphene oxide gel; (b) a carbon or graphite filler phase selected from carbon or graphite fiber, carbon or graphite nano-fiber, carbon nano-tube, carbon nano-rod, meso-phase carbon particle, meso-carbon micro-bead, exfoliated graphite flake with a thickness greater than 100 nm, exfoliated graphite or graphite worm, coke particle, needle coke, carbon black or acetylene black particle, activated carbon particle, or a combination thereof. The carbon or graphite filler phase is preferably in a particulate, filamentary, or rod-like form dispersed in and bonded by the unitary graphene matrix. This composite exhibits a combination of exceptional thermal conductivity, electrical conductivity, mechanical strength, surface hardness, and scratch resistance.