IP Library › Patent Application 18890855
Patent Application
App. No. 18/890,855

THERMAL INTERFACE MATERIAL

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Quick Facts
Patent No.
US None
App. No.
18/890,855
Abstract

A thermal interface material that conducts heat is disclosed. The thermal interface includes a bulk layer and at least one adhesive layer. The bulk layer includes a first acrylic rubber, plasticizer particles, and first filler particles, and the first filler particles are substantially aligned in a first direction. The first adhesive layer is disposed on a first side of the bulk material. The first adhesive layer has a greater tackiness than the bulk material. The first adhesive layer comprises a second acrylic rubber. The first direction is substantially perpendicular to a first surface of the first side on which the first adhesive layer is disposed.

Claims (89)

1 . A thermal interface material, comprising:

a bulk layer, wherein:

the bulk layer comprises a first acrylic rubber, plasticizer particles, and first filler particles; and

the first filler particles are substantially aligned in a first direction;

and at least one adhesive layer, comprising a first adhesive layer,

wherein: the first adhesive layer is disposed on a first side of the bulk material; the first adhesive layer has a greater tackiness than the bulk material; the first adhesive layer comprises a second acrylic rubber;

the first direction is perpendicular to a first surface of the first side on which the first adhesive layer is disposed.

2 . The thermal interface material of claim 1 , wherein the first adhesive layer further comprises second filler particles.

3 . The thermal interface material of claim 2 , wherein the second filler particles comprise graphite.

4 . The thermal interface material of claim 2 , wherein the second filler particles comprises boron nitride.

5 . The thermal interface material of claim 1 , wherein a concentration of the second acrylic rubber in the first adhesive layer is greater than a concentration of the first acrylic rubber in the bulk layer.

6 . The thermal interface material of claim 1 , wherein a concentration of the first acrylic rubber comprised in the bulk layer is higher at a mid-point of the bulk material between the first side of the bulk material and a second side of the bulk material, the second side being on a side opposing the first acrylic rubber.

7 . The thermal interface material of claim 1 , wherein:

the bulk material comprises a second side that is opposite to the first side;

a middle cross section of the bulk material corresponding to a having a thickness equal to 50% of a thickness between the first side and the second side has a first average concentration of the first acrylic rubber;

an end cross section of the bulk material corresponding to a section of the bulk material at one of the first side or the second side of the bulk material having a thickness equal to 50% of a thickness between the first side and the second side has a second average concentration of the first acrylic rubber; and

the first average concentration and the second average concentration are different.

8 . The thermal interface material of claim 7 , wherein the middle cross section of the bulk material is measured such that a mid-point of middle of the cross section in the direction between the first side and the second side corresponds to a mid-point of the bulk material in the direction between the first side and the second side.

9 . The thermal interface material of claim 7 , wherein the first average concentration is higher than the second average concentration.

10 . The thermal interface material of claim 1 , wherein the first filler particles comprise graphite.

11 . The thermal interface material of claim 1 , wherein the first filler particles comprise boron nitride.

12 . The thermal interface material of claim 1 , wherein the plasticizer particles comprise a polyester.

13 . The thermal interface material of claim 1 , wherein the plasticizer particles have a relatively high molecular weight.

14 . The thermal interface material of claim 1 , wherein the plasticizer particles have a molecular weight of at least 4,000.

15 . The thermal interface material of claim 1 , wherein the plasticizer particles have a molecular weight of at least 10,000.

16 . The thermal interface material of claim 1 , wherein the first acrylic rubber is a self healing material.

17 . The thermal interface material of claim 1 , wherein the plasticizer particles have an average viscosity of 850 at 80° C.

18 . The thermal interface material of claim 1 , wherein the plasticizer particles have a viscosity of between 875 and 1025 at 80° C.

19 . The thermal interface material of claim 1 , wherein the plasticizer particles have a viscosity of between 900 and 1000 at 80° C.

20 . The thermal interface material of claim 1 , wherein the plasticizer particles have an average viscosity of 930 at 25° C.

21 . The thermal interface material of claim 1 , wherein the plasticizer particles have a viscosity of between 825 and 1025 at 25° C.

22 . The thermal interface material of claim 1 , wherein the plasticizer particles have a viscosity of between 850 and 1000 at 25° C.

23 . The thermal interface material of claim 1 , wherein the plasticizer particles comprise a first set of plasticizer particles and a second set of plasticizer particles, and the first set of plasticizer particles and the second set of plasticizer particles are different.

24 . The thermal interface material of claim 23 , wherein the first set of plasticizer particles have a viscosity of between 900 and 1000 at 80° C., and the second set of plasticizer particles have a viscosity of between 850 and 1000 at 25° C.

25 . The thermal interface material of claim 23 , wherein the first set of plasticizer particles have a viscosity of between 875 and 1025 at 80° C., and the second set of plasticizer particles have a viscosity of between 825 and 1025 at 25° C.

26 . The thermal interface material of claim 1 , wherein the bulk layer comprises one or more channels of air that extend along the first direction.

27 . The thermal interface material of claim 1 , wherein the bulk layer comprises one or more channels of air that are substantially parallel to a direction in which the first filler particles are aligned.

28 . The thermal interface material of claim 1 , wherein the bulk layer comprises one or more channels of air that are substantially parallel to first direction.

29 . The thermal interface material of claim 1 , wherein the bulk layer comprises a set of gas pockets, and the gas bubbles are aligned substantially perpendicular to a direction in which the first filler particles are aligned.

30 . The thermal interface material of claim 29 , wherein the gas pockets correspond to air pockets.

31 . The thermal interface material of claim 1 , wherein the bulk layer has a greater thermal conductivity in the first direction than in a direction perpendicular to the first direction.

32 . The thermal interface material of claim 1 , wherein the bulk layer has a greatest thermal conductivity in the first direction.

33 . The thermal interface material of claim 1 , wherein an average molecular weight of the plasticizer particles is higher than an average molecular weight of the first acrylic rubber.

34 . The thermal interface material of claim 1 , wherein the at least one adhesive layer comprises a second adhesive layer disposed on a side of the bulk layer that opposes the first side of the bulk layer on which the first adhesive layer is disposed.

35 . The thermal interface material of claim 1 , wherein the first filler particles comprise ceramic particles.

36 . The thermal interface material of claim 1 , wherein the first filler particles are planar.

37 . The thermal interface material of claim 1 , wherein the substantial alignment of the first filler particles in the first direction comprises more than 50% of the first filler particles being aligned in the first direction.

38 . The thermal interface material of claim 37 , wherein the first filler particles being aligned in the first direction comprises a longest side of the first filler particles being parallel to the first direction.

39 . The thermal interface material of claim 1 , wherein:

the substantial alignment of the first filler particles in the first direction comprises at least 75% of the first filler particles being aligned in the first direction; and

the first filler particles being aligned in the first direction comprises a longest side of the first filler particles being parallel to the first direction.

40 . The thermal interface material of claim 1 , wherein:

the substantial alignment of the first filler particles in the first direction comprises at least 85% of the first filler particles being aligned in the first direction; and

the first filler particles being aligned in the first direction comprises a longest side of the first filler particles being parallel to the first direction.

41 . The thermal interface material of claim 1 , wherein:

the substantial alignment of the first filler particles in the first direction comprises at least 90% of the first filler particles being aligned in the first direction; and

the first filler particles being aligned in the first direction comprises a longest side of the first filler particles being parallel to the first direction.

42 . The thermal interface material of claim 1 , wherein:

the substantial alignment of the first filler particles in the first direction comprises at least 75% of the first filler particles being aligned in the first direction; and

the first filler particles being aligned in the first direction comprises a longest side of the first filler particles being within 5 degrees of the first direction.

43 . The thermal interface material of claim 1 , wherein:

the substantial alignment of the first filler particles in the first direction comprises at least 85% of the first filler particles being aligned in the first direction; and

the first filler particles being aligned in the first direction comprises a longest side of the first filler particles being within 5 degrees of the first direction.

44 . The thermal interface material of claim 1 , wherein:

the substantial alignment of the first filler particles in the first direction comprises at least 90% of the first filler particles being aligned in the first direction; and

the first filler particles being aligned in the first direction comprises a longest side of the first filler particles being within 5 degrees of the first direction.

45 . The thermal interface material of claim 1 , wherein:

the substantially alignment of the first filler particles in the first direction comprises at least 90% of the first filler particles being aligned in the first direction; and

the first filler particles being aligned in the first direction comprises a longest side of the first filler particles being within 5 degrees of the first direction.

46 . The thermal interface material of claim 1 , wherein first filler particles comprises a first subset of first filler particles and a second subset of the first filler particles.

47 . The thermal interface material of claim 46 , wherein:

an average size of the first subset of first filler particles is larger than an average size of the second subset of the first filler particles.

48 . The thermal interface material of claim 47 , wherein a thermal conductivity of the first subset of first filler particles if more uniform than a thermal conductivity of the second subset of first filler particles.

49 . The thermal interface material of claim 1 , wherein the bulk layer is 80% first filler particles by weight.

50 . The thermal interface material of claim 1 , wherein a first tensile strength of the thermal interface material along the first direction is different from a second tensile strength of the thermal interface material along a direction that is perpendicular to the first direction.

51 . The thermal interface material of claim 1 , wherein a tensile strength of the thermal interface material along the first direction is less than a tensile strength of the thermal interface material along a direction that is perpendicular to the first direction.

52 . The thermal interface material of claim 1 , wherein:

a first tensile strength of the thermal interface material along the first direction is different from a second tensile strength of the thermal interface material along a direction that is perpendicular to the first direction; and

a ratio of the second tensile strength to the first tensile strength is at least 1.5 to 1.

53 . The thermal interface material of claim 1 , wherein:

a first tensile strength of the thermal interface material along the first direction is different from a second tensile strength of the thermal interface material along a direction that is perpendicular to the first direction; and

a ratio of the second tensile strength to the first tensile strength is at least 2 to 1.

54 . The thermal interface material of claim 1 , wherein:

a first tensile strength of the thermal interface material along the first direction is different from a second tensile strength of the thermal interface material along a direction that is perpendicular to the first direction; and

a ratio of the second tensile strength to the first tensile strength is at least 2.5 to 1.

55 . The thermal interface material of claim 1 , wherein:

a first tensile strength of the thermal interface material along the first direction is different from a second tensile strength of the thermal interface material along a direction that is perpendicular to the first direction; and

a ratio of the second tensile strength to the first tensile strength is at least 3 to 1.

56 . The thermal interface material of claim 1 , wherein the first adhesive layer further comprises second filler particles.