Heat transfer composite, associated device and method
A heat transfer composite including a plurality of pyrolytic graphite parts and a non-carbonaceous matrix holding the pyrolytic graphite parts in a consolidated mass. In one embodiment, the heat transfer composite includes a quantity of pyrolytic graphite parts randomly distributed in the non-carbonaceous matrix. In another embodiment, the heat transfer composite includes distinct layers of pyrolytic graphite parts disposed in between the layers of sheets comprising non-carbonaceous materials. In still another embodiment, the heat transfer composite comprises a substrate containing at least one non-carbonaceous matrix containing at least one pyrolytic graphite part in a consolidated mass. The matrix is affixed to the substrate for conveying heat away from a heat source.
1 - 20 . (canceled)
21 . A heat transfer composite, comprising:
a plurality of pyrolytic graphite parts in a matrix containing a non-carbonaceous material, holding the plurality of pyrolytic graphite parts in a consolidated mass.
22 . The heat transfer composite of claim 21 , wherein the pyrolytic graphite parts are present in an amount of from about 30% to about 95% by volume of the heat transfer composite.
23 . The heat transfer composite of claim 21 , wherein the pyrolytic graphite parts are present in an amount greater than about 50% by volume of the heat transfer composite.
24 . The heat transfer composite of claim 21 , wherein the pyrolytic graphite parts are present in an amount of from about 40% to about 60% by volume of the heat transfer composite.
25 . The heat transfer composite of claim 21 , wherein the non-carbonaceous material comprises a material that can be diffusion bonded with the plurality of pyrolytic graphite parts.
26 . The heat transfer composite of claim 21 , wherein the non-carbonaceous material comprises an isotropic metal matrix.
27 . The heat transfer composite of claim 26 wherein the metal matrix comprises at least one of aluminum and aluminum alloys selected from the group Al—Mg; Al—Si; Al—Cu; Al—Ag; Al—Li; and Al—Be.
28 . The heat transfer composite of claim 27 , wherein the metal matrix includes at least an element to reduce the melting point of the metal matrix, selected from the group consisting of: Mn; Ni; Sn; and Zn.
29 . The heat transfer composite of claim 21 , wherein the plurality of pyrolytic graphite parts are recycled pyrolytic graphite parts.
30 . The heat transfer composite of claim 21 , wherein the pyrolytic graphite parts comprise at least one of pyrolytic graphite, highly oriented pyrolytic graphite, compression annealed pyrolytic graphite and mixtures thereof.
31 . The heat transfer composite of claim 30 , wherein the pyrolytic graphite parts have an in-plane (a-b direction) thermal conductivity ranging from 300 W/m-° K to 1800 W/m-° K and random sizes and shapes.
32 . The heat transfer composite of claim 21 , wherein the pyrolytic graphite parts in-plane (a-b direction) is randomly distributed in the composite.
33 . The heat transfer composite of claim 32 , wherein the pyrolytic graphite parts in-plane (a-b direction) is substantially parallel to the surface of the heat transfer composite.
34 . The heat transfer composite of claim 21 , wherein the non-carbonaceous matrix comprises a plurality of non-carbonaceous sheet layers, and wherein the plurality of pyrolytic graphite parts are disposed in-between the non-carbonaceous sheet layers.
35 . The heat transfer composite of claim 34 , wherein the pyrolytic graphite parts in-plane (a-b direction) is substantially parallel to the surface of the heat transfer composite.
36 . The heat transfer composite of claim 35 , wherein the pyrolytic graphite parts are placed in a periodic pattern within the heat transfer composite.
37 . The heat transfer composite of claim 34 , wherein the non-carbonaceous matrix comprises a plurality of aluminum sheet layers, and wherein the plurality of pyrolytic graphite parts are disposed in between the aluminum sheet layers, wherein there is a least one pyrolytic graphite part for each layer of aluminum sheet.
38 . The heat transfer composite of claim 37 , wherein the pyrolytic graphite parts in-plane (a-b direction) is substantially parallel to the surface of the heat transfer composite.
39 . The heat transfer composite of claim 38 , wherein the pyrolytic graphite parts are placed in a periodic pattern within the heat transfer composite.
40 . The heat transfer composite of claim 34 , wherein the sheet layers are hot-pressed at a temperature of at least 400° C. and at least 300 psi.
41 . The heat transfer composite of claim 34 , wherein the sheet layers have a thickness of at least 5 mils.
42 . The heat transfer composite of claim 34 , wherein the sheet layers have a nominal thickness from 1/32″ to 5/18″.
43 . The heat transfer composite of claim 21 , wherein the composite has a thickness of at least 10 mils.
44 . A method of fabricating a heat transfer composite, comprising the steps of:
disposing a plurality of pyrolytic graphite parts in a matrix of a non-carbonaceous material, forming a mass; and
heating the mass of pyrolytic graphite parts in the non-carbonaceous matrix to a sufficient temperature and pressure to embed the pyrolytic graphite parts in the non-carbonaceous matrix.
45 . The method of claim 44 , wherein the non-carbonaceous material comprises an isotropic metal matrix.
46 . The method of claim 44 , wherein the pyrolytic graphite parts are present in an amount of from about 30% to about 95% by volume of the heat transfer composite.
47 . The method of claim 44 , wherein the pyrolytic graphite parts are present in an amount greater than about 50% by volume of the heat transfer composite.
48 . The method of claim 44 , wherein the pyrolytic graphite parts are present in an amount of from about 40% to about 60% by volume of the heat transfer composite.
49 . The method of claim 44 , wherein the metal includes an alloy selected from the group consisting of: Al—Mg; Al—Si; Al—Cu; Al—Ag; Al—Li; and Al—Be.
50 . The method of claim 49 , wherein the metal matrix includes an element to reduce the melting point of the metal matrix, the element being selected from the group consisting of: Mn; Ni; Sn; and Zn.
51 . The method of claim 44 , wherein the pyrolytic graphite parts comprises a mixture of pyrolytic graphite, highly oriented pyrolytic graphite, compression annealed pyrolytic graphite parts, having an in-plane (a-b direction) thermal conductivity ranging from 300 W/m-° K to 1800 W/m-° K.
52 . The method of claim 44 , wherein the step of disposing the plurality of pyrolytic graphite parts in the non-carbonaceous matrix comprises distributing the plurality of pyrolytic graphite parts in between layers comprising a non-carbonaceous material.
53 . A heat transfer device comprising the heat transfer composite of claim 21 .
54 . The heat transfer composite of claim 21 , further comprising a non-carbonaceous material substrate having affixed therein at least one of said matrix, wherein the matrix comprises at least one pyrolytic graphite part and overlaps a heat source for conveying heat away from said heat source.
55 . The heat transfer composite of claim 54 , wherein the substrate is substantially flat and the in-plane (a-b direction) of the at least one pyrolytic graphite part is substantially parallel to the surface of the heat transfer composite.
56 . The heat transfer composite of claim 54 , wherein the pyrolytic graphite part(s) has an in-plane thermal conductivity of at least about 300 W/m-° K in a-b direction and less than about 20 W/m-° K in c direction.
57 . The heat transfer composite of claim 54 , wherein said matrix is affixed to the substrate by a process which is at least one selected from the group consisting of epoxy bonding, mechanical screws, solder, braze, press fitting, compression fitting, hot isostatic pressing and diffusion bond process.
58 . The heat transfer composite of claim 54 , wherein the substrate of non-carbonaceous material comprises an isotropic metal comprising at least one of aluminum and aluminum alloys selected from the group Al—Mg; Al—Si; Al—Cu; Al—Ag; Al—Li; and Al—Be.
59 . The heat transfer composite of claim 58 , wherein the substrate includes at least an element to reduce the melting point of the metal substrate, selected from the group consisting of: Mn; Ni; Sn; and Zn.
60 . The heat transfer composite of claim 54 , wherein matrix comprises a non-carbonaceous material that can be diffusion bonded with at least one pyrolytic graphite part.
61 . The heat transfer composite of claim 60 , wherein the non-carbonaceous material of the matrix comprises an isotropic metal matrix.
62 . The heat transfer composite of claim 61 , wherein the metal matrix comprises at least one of aluminum and aluminum alloys selected from the group Al—Mg; Al—Si; Al—Cu; Al—Ag; Al—Li; and Al—Be.
63 . The heat transfer composite of claim 62 , wherein the metal matrix includes at least an element to reduce the melting point of the metal matrix, selected from the group consisting of: Mn; Ni; Sn; and Zn.
64 . The heat transfer composite of claim 54 , wherein the at least one pyrolytic graphite part of the matrix is recycled pyrolytic graphite.
65 . The heat transfer composite of claim 64 , wherein the pyrolytic graphite part comprises at least one of pyrolytic graphite, highly oriented pyrolytic graphite, compression annealed pyrolytic graphite, having an in-plane (a-b direction) thermal conductivity ranging from about 300 W/m-° K to 1800 W/m-° K.
66 . The heat transfer composite of claim 54 , wherein the pyrolytic graphite part(s) is present in an amount that ranges from about 10 percent to about 50 percent by volume of the heat transfer composite.
67 . The heat transfer composite of claim 54 , wherein the pyrolytic graphite part(s) is present in an amount that ranges from about 10 percent to about 30 percent by volume of the heat transfer composite.
68 . The heat transfer composite of claim 54 , wherein the pyrolytic graphite part(s) is present in an amount that ranges from about 20 percent to about 30 percent by volume of the heat transfer composite.
69 . The heat transfer composite of claim 54 , wherein the pyrolytic graphite part(s) is at least one of random sizes, random shapes, different sizes, and different shapes.
70 . The heat transfer composite of claim 54 , wherein the matrix comprises a plurality of non-carbonaceous sheet layers, and wherein the at least one pyrolytic graphite part is disposed on and/or in-between the non-carbonaceous sheet layers.
71 . The heat transfer composite of claim 70 , wherein the non-carbonaceous sheet layers are aluminum, and wherein the at least one pyrolytic graphite part is disposed on and/or in-between the aluminum sheet layers.
72 . The heat transfer composite of claim 70 , wherein the at least one pyrolytic graphite part is placed in a periodic pattern within the heat transfer composite.
73 . The heat transfer composite of claim 71 , wherein the layered sheets are hot-pressed at a temperature of at least 400° C. and at least 300 psi.
74 . The heat transfer composite of claim 71 , wherein each of the aluminum sheets have an average thickness of at least 10 mils.
75 . The heat transfer composite of claim 54 , wherein the composite has a thickness of at least 10 mils.
76 . A method for constructing the heat transfer composite of claim 54 , comprising the steps of:
affixing at least one matrix to the substrate; and,
arranging the matrix within the substrate to overlap a heat source for conveying heat away from said heat source.
77 . The method of claim 76 , where the at least one pyrolytic graphite part has an in-plane thermal conductivity of at least about 300 W/m-° K in a-b direction and less than about 20 W/m-° K in c direction.
78 . The method of claim 76 , wherein the wherein the substrate of non-carbonaceous material comprises an isotropic metal.
79 . The method of claim 78 , wherein the metal substrate includes an alloy selected from the group consisting of: Al—Mg; Al—Si; Al—Cu; Al—Ag; Al—Li; and Al—Be.
80 . The method of claim 79 , wherein the substrate includes an element to reduce the melting point of the metal, the element being selected from the group consisting of: Mn; Ni; Sn; and Zn.
81 . The method of claim 76 , wherein matrix comprises a non-carbonaceous material that can be diffusion bonded with at least one pyrolytic graphite part.
82 . The method of claim 81 , wherein the non-carbonaceous material of the matrix comprises an isotropic metal matrix.
83 . The method of claim 82 , wherein the metal matrix comprises at least one of aluminum and aluminum alloys selected from the group Al—Mg; Al—Si; Al—Cu; Al—Ag; Al—Li; and Al—Be.
84 . The method of claim 83 , wherein the metal matrix includes at least an element to reduce the melting point of the metal matrix, selected from the group consisting of: Mn; Ni; Sn; and Zn.
85 . The method of claim 76 , wherein the pyrolytic graphite part comprises at least one of pyrolytic graphite, highly oriented pyrolytic graphite, compression annealed pyrolytic graphite, having an in-plane (a-b direction) thermal conductivity ranging from about 300 W/m-° K to 1800 W/m-° K.
86 . A heat transfer device comprising the heat transfer composite of claim 54 .