IP Library › Granted Patent US 12,453,042

Granted Patent B2

US 12,453,042 · App. 19/000,555 · Granted Oct 21, 2025

Metallic thermal interface materials and associated devices, systems, and methods

Inventor: Himanshu Pokharna (Saratoga, CA)

Assignee: DEEIA INC.

H05K7/20254 C09K5/06 G06F1/20 H01M10/613 H01M10/653 H01M10/6551 H01M10/6567 H05K7/20263 G06F2200/201

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Quick Facts

Patent No.: US 12,453,042
App. No.: 19/000,555
Granted: Oct 21, 2025
Kind: B2

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USPTO Patent Center↗ Full Patent PDF↗

Abstract

A heat-transfer component defines a thermal-interface surface and has a composite thermal-interface material bonded to the thermal-interface surface. The composite thermal-interface material comprises a particulate filler material dispersed within a metallic carrier material. With a thermal-interface material bonded to the thermal-interface surface, the thermal-contact resistance between the thermal-interface material and the heat-transfer component can be reduced compared to conventional thermal-interface materials, including conventional metallic thermal-interface materials. The particulate filler material can have a higher bulk thermal conductivity than the metallic carrier material and can be wetted by the metallic carrier material, providing a bulk thermal conductivity of the composite thermal-interface material that is higher than that of the carrier material without the particulate filler material. Such materials can relieve thermally induced mechanical stresses across an interface between materials having different coefficients of thermal expansion. Some electrical devices include a heat generating component cooled by such a heat-transfer component.

Claims (106)

1. A heat-transfer component, comprising:

a thermal-interface surface; and

a composite thermal-interface material comprising a metallic carrier material and a particulate filler, wherein the particulate filler comprises a coating or plating material and a particulate material, wherein the coating or plating material at least partly envelopes the particulate material, and wherein the coating or plating material has higher wettability by the metallic carrier material than the particulate material, the composite thermal-interface material bonded to the thermal-interface surface, wherein the metallic carrier material begins to melt at a temperature between about 15° C. and about 40° C.

2. The heat-transfer component according to claim 1 , wherein the coating or plating material comprises one or more of tin, zinc, copper, nickel, gold, platinum, silver, cadmium, titanium palladium, brass, bronze, chromium, gallium oxide.

3. The heat-transfer component according to claim 1 , wherein the particulate filler comprises a particulate form of one or more of copper, nickel, silver, gold, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

4. The heat-transfer component according to claim 1 , wherein the metallic carrier has less than about 10% (weight) Gallium.

5. The heat-transfer component according to claim 1 , wherein the particulate filler comprises one or more of an alloy of copper, an alloy of silver, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

6. The heat-transfer component according to claim 1 , wherein the heat-transfer component is an integrated heat spreader configured to overlie an integrated-circuit die, the thermal-interface surface being a first major surface of the integrated heat spreader, the integrated heat spreader defining a second major surface positioned opposite the thermal-interface surface, the second major surface being configured to face the integrated-circuit die and the first major surface being configured to face a heat-removal device.

7. The heat-transfer component according to claim 1 , wherein the heat-transfer component is a heat-removal device configured to dissipate heat received from heat-generating electronic component, the heat-removal device having a base and the thermal-interface surface being a first major surface of the base, the base further defining a second major surface opposite the first major surface, the heat-removal device further comprising a plurality of fins extending from the second major surface.

8. The electrical device according to claim 1 , wherein the coating or plating material comprises one or more of tin, zinc, copper, nickel, gold, platinum, silver, cadmium, titanium palladium, brass, bronze, chromium, gallium oxide.

9. A heat-transfer component, comprising:

a thermal-interface surface; and

a composite thermal-interface material comprising a metallic carrier material and a particulate filler, the composite thermal-interface material bonded to the thermal-interface surface, wherein the metallic carrier material begins to melt at a temperature between about 15° C. and about 40° C., wherein the metallic carrier material is a non-eutectic mixture comprising one or more of Bismuth, Indium, Tin, Silver and Gallium, wherein the metallic carrier material fully melts at a temperature between about 130° C. and about 320° C., wherein a fully liquid phase of the metallic carrier material begins to freeze at a temperature between about 130° C. and about 320° C. and fully freezes at a temperature between about 15° C. and about 40° C.

10. The heat-transfer component according to claim 9 , wherein the metallic carrier has less than about 10% (weight) Gallium.

11. The heat-transfer component according to claim 9 , wherein the particulate filler comprises one or more of an alloy of copper, an alloy of silver, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

12. The heat-transfer component according to claim 9 , wherein the heat-transfer component is an integrated heat spreader configured to overlie an integrated-circuit die, the thermal-interface surface being a first major surface of the integrated heat spreader, the integrated heat spreader defining a second major surface positioned opposite the thermal-interface surface, the second major surface being configured to face the integrated-circuit die and the first major surface being configured to face a heat-removal device.

13. The heat-transfer component according to claim 9 , wherein the heat-transfer component is a heat-removal device configured to dissipate heat received from heat-generating electronic component, the heat-removal device having a base and the thermal-interface surface being a first major surface of the base, the base further defining a second major surface opposite the first major surface, the heat-removal device further comprising a plurality of fins extending from the second major surface.

14. A heat-transfer component comprising:

a thermal-interface surface; and

a composite thermal-interface material comprising a metallic carrier material and a particulate filler, wherein the particulate filler comprises a particulate form of diamond coated in part by gallium oxide, the composite thermal-interface material bonded to the thermal-interface surface, wherein the metallic carrier material begins to melt at a temperature between about 15° C. and about 40° C.

15. The heat-transfer component according to claim 14 , wherein the metallic carrier has less than about 10% (weight) Gallium.

16. The heat-transfer component according to claim 14 , wherein the particulate filler comprises one or more of an alloy of copper, an alloy of silver, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

17. The heat-transfer component according to claim 14 , wherein the heat-transfer component is an integrated heat spreader configured to overlie an integrated-circuit die, the thermal-interface surface being a first major surface of the integrated heat spreader, the integrated heat spreader defining a second major surface positioned opposite the thermal-interface surface, the second major surface being configured to face the integrated-circuit die and the first major surface being configured to face a heat-removal device.

18. The heat-transfer component according to claim 14 , wherein the heat-transfer component is a heat-removal device configured to dissipate heat received from heat-generating electronic component, the heat-removal device having a base and the thermal-interface surface being a first major surface of the base, the base further defining a second major surface opposite the first major surface, the heat-removal device further comprising a plurality of fins extending from the second major surface.

19. An electrical device, comprising:

a heat-generating component defining a first thermal-interface surface;

a heat-transfer component defining a second thermal-interface surface; and

a composite thermal-interface material comprising a metallic carrier material and a particulate filler, wherein the particulate filler comprises a particulate form of one or more of copper, nickel, silver, gold, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride, wherein the metallic carrier material is bonded to the first thermal-interface, the second thermal-interface surface, or both, wherein the metallic carrier material begins to melt between about 15° C. and about 40° C., wherein the metallic carrier material fully melts at a temperature between about 130° C. and about 320° C.

20. The electrical device according to claim 19 , wherein the metallic carrier material comprises a non-eutectic mixture comprising one or more of Bismuth, Indium, Tin, Silver and Gallium.

21. The electrical device according to claim 20 , wherein the metallic carrier material has less than about 10% (weight) Gallium.

22. The electrical device according to claim 20 , wherein the particulate material comprises one or more of an alloy of copper, an alloy of silver, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

23. The electrical device according to claim 19 , wherein a fully liquid phase of the metallic carrier material begins to freeze at a temperature between about 130° C. and about 320° C. and fully freezes at a temperature between about 15° C. and about 40° C.

24. The electrical device according to claim 19 , wherein the heat-transfer component is an integrated heat spreader configured to overlie an integrated-circuit die, the thermal-interface surface being a first major surface of the integrated heat spreader, the integrated heat spreader defining a second major surface positioned opposite the thermal-interface surface, the second major surface being configured to face the integrated-circuit die and the first major surface being configured to face a heat-removal device, wherein each of the integrated heat spreader and the integrated-circuit die has a corresponding coefficient of thermal expansion different from the other.

25. The electrical device according to claim 19 , wherein the heat-transfer component is a heat-removal device configured to dissipate heat received from heat-generating electronic component, the heat-removal device having a base and the thermal-interface surface being a first major surface of the base, the base further defining a second major surface opposite the first major surface, the heat-removal device further comprising a plurality of fins extending from the second major surface.

26. The electrical device according to claim 19 , wherein the heat-generating component is an electronic processing unit.

27. The electrical device according to claim 19 , wherein the heat-generating component is an electrical storage battery.

28. The electrical device according to claim 19 , wherein the coating or plating material comprises one or more of tin, zinc, copper, nickel, gold, platinum, silver, cadmium, titanium palladium, brass, bronze, chromium, gallium oxide.

29. The electrical device according to claim 19 , wherein the particulate filler comprises a coating or plating material and a particulate material, wherein the coating or plating material at least partly envelopes the particulate material.

30. An electrical device, comprising:

a heat-generating component defining a first thermal-interface surface;

a heat-transfer component defining a second thermal-interface surface; and

a composite thermal-interface material comprising a metallic carrier material and a particulate filler, wherein the metallic carrier material is bonded to the first thermal-interface, the second thermal-interface surface, or both, wherein the metallic carrier material begins to melt between about 15° C. and about 40° C., wherein the particulate filler comprises a coating or plating material and a particulate material, wherein the coating or plating material at least partly envelopes the particulate material, wherein the coating or plating material has higher wettability by the metallic carrier material than the particulate filler alone.

31. The electrical device according to claim 30 , wherein the coating or plating material comprises one or more of tin, zinc, copper, nickel, gold, platinum, silver, cadmium, titanium palladium, brass, bronze, chromium, gallium oxide.

32. The electrical device according to claim 30 , wherein the particulate filler comprises a particulate form of one or more of copper, nickel, silver, gold, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

33. The electrical device according to claim 30 , wherein the metallic carrier material comprises a non-eutectic mixture comprising one or more of Bismuth, Indium, Tin, Silver and Gallium.

34. The electrical device according to claim 33 , wherein the metallic carrier material has less than about 10% (weight) Gallium.

35. The electrical device according to claim 34 , wherein the particulate material comprises one or more of an alloy of copper, an alloy of silver, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

36. The electrical device according to claim 30 , wherein the metallic carrier material fully melts at a temperature between about 130° C. and about 320° C.

37. The electrical device according to claim 30 , wherein a fully liquid phase of the metallic carrier material begins to freeze at a temperature between about 130° C. and about 320° C. and fully freezes at a temperature between about 15° C. and about 40° C.

38. The electrical device according to claim 30 , wherein the heat-transfer component is an integrated heat spreader configured to overlie an integrated-circuit die, the thermal-interface surface being a first major surface of the integrated heat spreader, the integrated heat spreader defining a second major surface positioned opposite the thermal-interface surface, the second major surface being configured to face the integrated-circuit die and the first major surface being configured to face a heat-removal device, wherein each of the integrated heat spreader and the integrated-circuit die has a corresponding coefficient of thermal expansion different from the other.

39. The electrical device according to claim 30 , wherein the heat-transfer component is a heat-removal device configured to dissipate heat received from heat-generating electronic component, the heat-removal device having a base and the thermal-interface surface being a first major surface of the base, the base further defining a second major surface opposite the first major surface, the heat-removal device further comprising a plurality of fins extending from the second major surface.

40. The electrical device according to claim 30 , wherein the heat-generating component is an electronic processing unit.

41. The electrical device according to claim 30 , wherein the heat-generating component is an electrical storage battery.

42. A heat-transfer component, comprising:

a thermal-interface surface; and

43. The heat-transfer component according to claim 42 , wherein the coating or plating material comprises one or more of tin, zinc, copper, nickel, gold, platinum, silver, cadmium, titanium palladium, brass, bronze, chromium, gallium oxide.

44. The heat-transfer component according to claim 42 , wherein the particulate filler comprises a particulate form of one or more of copper, nickel, silver, gold, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

45. The heat-transfer component according to claim 42 , wherein the metallic carrier has less than about 10% (weight) Gallium.

46. The heat-transfer component according to claim 42 , wherein the particulate filler comprises one or more of an alloy of copper, an alloy of silver, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

47. The heat-transfer component according to claim 42 , wherein the heat-transfer component is an integrated heat spreader configured to overlie an integrated-circuit die, the thermal-interface surface being a first major surface of the integrated heat spreader, the integrated heat spreader defining a second major surface positioned opposite the thermal-interface surface, the second major surface being configured to face the integrated-circuit die and the first major surface being configured to face a heat-removal device.

48. The heat-transfer component according to claim 42 , wherein the heat-transfer component is a heat-removal device configured to dissipate heat received from heat-generating electronic component, the heat-removal device having a base and the thermal-interface surface being a first major surface of the base, the base further defining a second major surface opposite the first major surface, the heat-removal device further comprising a plurality of fins extending from the second major surface.

49. The electrical device according to claim 42 , wherein the coating or plating material comprises one or more of tin, zinc, copper, nickel, gold, platinum, silver, cadmium, titanium palladium, brass, bronze, chromium, gallium oxide.

50. A heat-transfer component, comprising:

a thermal-interface surface; and

a composite thermal-interface material comprising a metallic carrier material and a particulate filler, the composite thermal-interface material bonded to the thermal-interface surface, wherein the metallic carrier material is a non-eutectic mixture comprising one or more of Bismuth, Indium, Tin, Silver and Gallium, wherein the metallic carrier material fully melts at a temperature between about 130° C. and about 320° C., wherein a fully liquid phase of the metallic carrier material begins to freeze at a temperature between about 130° C. and about 320° C.

51. The heat-transfer component according to claim 50 , wherein the metallic carrier has less than about 10% (weight) Gallium.

52. The heat-transfer component according to claim 50 , wherein the particulate filler comprises one or more of an alloy of copper, an alloy of silver, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

53. The heat-transfer component according to claim 50 , wherein the heat-transfer component is an integrated heat spreader configured to overlie an integrated-circuit die, the thermal-interface surface being a first major surface of the integrated heat spreader, the integrated heat spreader defining a second major surface positioned opposite the thermal-interface surface, the second major surface being configured to face the integrated-circuit die and the first major surface being configured to face a heat-removal device.

54. The heat-transfer component according to claim 50 , wherein the heat-transfer component is a heat-removal device configured to dissipate heat received from heat-generating electronic component, the heat-removal device having a base and the thermal-interface surface being a first major surface of the base, the base further defining a second major surface opposite the first major surface, the heat-removal device further comprising a plurality of fins extending from the second major surface.

55. A heat-transfer component comprising:

a thermal-interface surface; and

56. The heat-transfer component according to claim 55 , wherein the metallic carrier has less than about 10% (weight) Gallium.

57. The heat-transfer component according to claim 55 , wherein the particulate filler comprises one or more of an alloy of copper, an alloy of silver, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

58. The heat-transfer component according to claim 55 , wherein the heat-transfer component is an integrated heat spreader configured to overlie an integrated-circuit die, the thermal-interface surface being a first major surface of the integrated heat spreader, the integrated heat spreader defining a second major surface positioned opposite the thermal-interface surface, the second major surface being configured to face the integrated-circuit die and the first major surface being configured to face a heat-removal device.

59. The heat-transfer component according to claim 55 , wherein the heat-transfer component is a heat-removal device configured to dissipate heat received from heat-generating electronic component, the heat-removal device having a base and the thermal-interface surface being a first major surface of the base, the base further defining a second major surface opposite the first major surface, the heat-removal device further comprising a plurality of fins extending from the second major surface.

60. An electrical device, comprising:

a heat-generating component defining a first thermal-interface surface;

a heat-transfer component defining a second thermal-interface surface; and

a composite thermal-interface material comprising a metallic carrier material and a particulate filler, wherein the particulate filler comprises a particulate form of one or more of copper, nickel, silver, gold, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride, wherein the metallic carrier material is bonded to the first thermal-interface, the second thermal-interface surface, or both, wherein the metallic carrier material fully melts at a temperature between about 130° C. and about 320° C.

61. The electrical device according to claim 60 , wherein the metallic carrier material comprises a non-eutectic mixture comprising one or more of Bismuth, Indium, Tin, Silver and Gallium.

62. The electrical device according to claim 61 , wherein the metallic carrier material has less than about 10% (weight) Gallium.

63. The electrical device according to claim 62 , wherein the particulate material comprises one or more of an alloy of copper, an alloy of silver, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

64. The electrical device according to claim 60 , wherein a fully liquid phase of the metallic carrier material begins to freeze at a temperature between about 130° C. and about 320° C.

65. The electrical device according to claim 60 , wherein the heat-transfer component is an integrated heat spreader configured to overlie an integrated-circuit die, the thermal-interface surface being a first major surface of the integrated heat spreader, the integrated heat spreader defining a second major surface positioned opposite the thermal-interface surface, the second major surface being configured to face the integrated-circuit die and the first major surface being configured to face a heat-removal device, wherein each of the integrated heat spreader and the integrated-circuit die has a corresponding coefficient of thermal expansion different from the other.

66. The electrical device according to claim 60 , wherein the heat-transfer component is a heat-removal device configured to dissipate heat received from heat-generating electronic component, the heat-removal device having a base and the thermal-interface surface being a first major surface of the base, the base further defining a second major surface opposite the first major surface, the heat-removal device further comprising a plurality of fins extending from the second major surface.

67. The electrical device according to claim 60 , wherein the heat-generating component is an electronic processing unit.

68. The electrical device according to claim 60 , wherein the heat-generating component is an electrical storage battery.

69. The electrical device according to claim 60 , wherein the coating or plating material comprises one or more of tin, zinc, copper, nickel, gold, platinum, silver, cadmium, titanium palladium, brass, bronze, chromium, gallium oxide.

70. The electrical device according to claim 60 , wherein the particulate filler comprises a coating or plating material and a particulate material, wherein the coating or plating material at least partly envelopes the particulate material.

71. An electrical device, comprising:

a heat-generating component defining a first thermal-interface surface;

a heat-transfer component defining a second thermal-interface surface; and

a composite thermal-interface material comprising a metallic carrier material and a particulate filler, wherein the metallic carrier material is bonded to the first thermal-interface, the second thermal-interface surface, or both, wherein the particulate filler comprises a coating or plating material and a particulate material, wherein the coating or plating material at least partly envelopes the particulate material, wherein the coating or plating material has higher wettability by the metallic carrier material than the particulate filler alone.

72. The electrical device according to claim 71 , wherein the coating or plating material comprises one or more of tin, zinc, copper, nickel, gold, platinum, silver, cadmium, titanium palladium, brass, bronze, chromium, gallium oxide.

73. The electrical device according to claim 71 , wherein the particulate filler comprises a particulate form of one or more of copper, nickel, silver, gold, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

74. The electrical device according to claim 71 , wherein the metallic carrier material comprises a non-eutectic mixture comprising one or more of Bismuth, Indium, Tin, Silver and Gallium.

75. The electrical device according to claim 74 , wherein the metallic carrier material has less than about 10% (weight) Gallium.

76. The electrical device according to claim 75 , wherein the particulate material comprises one or more of an alloy of copper, an alloy of silver, aluminum oxide, aluminum nitride, silicon carbide, diamond, zinc oxide, and boron nitride.

77. The electrical device according to claim 71 , wherein the metallic carrier material fully melts at a temperature between about 130° C. and about 320° C.

78. The electrical device according to claim 71 , wherein a fully liquid phase of the metallic carrier material begins to freeze at a temperature between about 130° C. and about 320° C.

79. The electrical device according to claim 71 , wherein the heat-transfer component is an integrated heat spreader configured to overlie an integrated-circuit die, the thermal-interface surface being a first major surface of the integrated heat spreader, the integrated heat spreader defining a second major surface positioned opposite the thermal-interface surface, the second major surface being configured to face the integrated-circuit die and the first major surface being configured to face a heat-removal device, wherein each of the integrated heat spreader and the integrated-circuit die has a corresponding coefficient of thermal expansion different from the other.

80. The electrical device according to claim 71 , wherein the heat-transfer component is a heat-removal device configured to dissipate heat received from heat-generating electronic component, the heat-removal device having a base and the thermal-interface surface being a first major surface of the base, the base further defining a second major surface opposite the first major surface, the heat-removal device further comprising a plurality of fins extending from the second major surface.

81. The electrical device according to claim 71 , wherein the heat-generating component is an electronic processing unit.

82. The electrical device according to claim 71 , wherein the heat-generating component is an electrical storage battery.

Assignments (1)

ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 23, 2025

From: POKHARNA, HIMANSHU

To: DEEIA INC.

Reel/Frame 072349/0826 →

Continuity (10)

Continuation In Part PCTUS2024016585 · Feb 20, 2024

Continuation In Part 18212623 · Jun 21, 2023

Continuation In Part PCTUS2022039196 · Aug 2, 2022

Continuation In Part PCTUS2023025894 · Jun 21, 2023

Continuation In Part 17879630 · Aug 2, 2022

Continuation In Part 18212623 · Jun 21, 2023

Continuation In Part 17879630 · Aug 2, 2022

Provisional Application 63485925 · Feb 19, 2023

Provisional Application 63354175 · Jun 21, 2022

Related Publication 20250126746A1 · Apr 17, 2025

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