Multi-scale hybrid spherical graphite composites: a light weight thermal interface material with high thermal...

Area of Science:

• Materials Science
• Nanotechnology
• Thermal Engineering

Background:

• Spherical graphite powders possess low density and high thermal conductivity, making them suitable for lightweight thermal interface materials.
• Traditional aluminum oxide (Al2O3)-derived composites have limitations in terms of density and thermal performance.

Purpose of the Study:

• To develop novel spherical artificial graphite composites with improved thermal conductivity and reduced density.
• To optimize the formulation of multi-scale spherical graphite particles using advanced calculation methods.
• To establish predictive relationships between filler properties and composite performance.

Main Methods:

• Development of spherical artificial graphite derived composites.
• Application of quadratic programming to particle packing theory for formulation optimization.
• Characterization of thermal conductivity and bulk density.
• Establishment of correlations between filler tap density and composite thermal conductivity.

Main Results:

• Optimized composites achieved a thermal conductivity of 1.994 W m⁻¹ K⁻¹, a 1.72-fold increase over single-particle composites.
• Bulk density was significantly reduced to 1.812 g cm⁻³, compared to 2.31 g cm⁻³ for Al2O3 composites.
• Predictive relationships were established between graphite powder tap density and composite thermal conductivity.

Conclusions:

• Spherical artificial graphite composites present a superior alternative to Al2O3 for lightweight thermal management applications.
• The proposed optimization method and predictive models offer a valuable strategy for designing advanced thermal interface materials.
• This research provides a pathway for enhancing thermal management in electronic devices through optimized filler particle design.