Fabrication and Characterization of Al₂O₃-Siloxane Composite Thermal Pads for Thermal Interface Materials

In this study, Al₂O₃-siloxane composite thermal pads were fabricated using a tape-casting technique, and the thermal conductivity effect of the Al₂O₃ nanoparticle powder synthesized using a flame fusion process on siloxane composite thermal pads was investigated. Furthermore, various case studies were implemented, wherein the synthesized Al₂O₃ nanoparticle powder was subjected to different surface treatments, including dehydration, decarbonization, and silylation, to obtain Al₂O₃-siloxane composite thermal pads with high thermal conductivity. The experimental results confirmed that the thermal conductivity of the Al₂O₃-siloxane composite pads improved when fabricated using surface-treated Al₂O₃ nanoparticle powder synthesized with an optimally spheroidized crystal structure compared to that produced using non-treated Al₂O₃ nanoparticle powder. Therefore, this study provides guidelines for fabricating Al₂O₃-siloxane composite thermal pads with high thermal conductivity in the field of thermal interface materials.