Compressible thermally conductive articles
First Claim
1. A compressible thermally conductive sheet having a first and second heat transfer surface and a plurality of through holes connecting the first and second heat transfer surfaces to provide a thermal pathway there between, wherein the sheet comprises a polymeric foam pad having through holes that are filled with a non-foamed thermally conductive composition comprising thermally conductive particulate filler dispersed in a polymeric, matrix, wherein the particulate filler consists of a material selected from the group consisting of metal oxides, non-metal oxides, nitrides, carbides, borides and combinations thereof, wherein the filler has a thermal conductivity of about 0.5 W/m-K to about 1000 W/m-K;
- wherein the compressible thermally conductive sheet has a thermal conductivity of at least 0.5 W/m-K;
wherein the density of the through holes is 100,000 holes per square meter to 2 million holes per square meter;
wherein the metal oxide is aluminum oxide, magnesium oxide, beryllium oxide, or combinations thereof; and
wherein the non-foamed thermally conductive composition is free from filler particles comprising metal.
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Accused Products
Abstract
A compressible thermally conductive sheet comprises a plurality of through holes in a foam material substantially connecting first and second heat transfer surfaces to provide thermal pathways between surfaces. The though holes are filled with a non-foam thermally conductive composition in which thermally-conductive particulate filler is dispersed in a polymeric matrix. Also disclosed is a heat management assembly comprising the compressible thermally conductive sheet.
42 Citations
25 Claims
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1. A compressible thermally conductive sheet having a first and second heat transfer surface and a plurality of through holes connecting the first and second heat transfer surfaces to provide a thermal pathway there between, wherein the sheet comprises a polymeric foam pad having through holes that are filled with a non-foamed thermally conductive composition comprising thermally conductive particulate filler dispersed in a polymeric, matrix, wherein the particulate filler consists of a material selected from the group consisting of metal oxides, non-metal oxides, nitrides, carbides, borides and combinations thereof, wherein the filler has a thermal conductivity of about 0.5 W/m-K to about 1000 W/m-K;
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wherein the compressible thermally conductive sheet has a thermal conductivity of at least 0.5 W/m-K; wherein the density of the through holes is 100,000 holes per square meter to 2 million holes per square meter; wherein the metal oxide is aluminum oxide, magnesium oxide, beryllium oxide, or combinations thereof; and wherein the non-foamed thermally conductive composition is free from filler particles comprising metal. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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24. A compressible thermally conductive sheet having a first and second heat transfer surface and a plurality of through holes substantially transverse to the first and second heat transfer surfaces to provide a thermal pathway there between;
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wherein said sheet comprises a foam polymeric pad having through holes that are filled with a non-foamed thermally conductive composition comprising about 20% to 80% by weight of dispersed thermally-conductive particulate filler, wherein the particulate filler consists of ceramic having on average a thermal conductivity of 25 to 500 W/m-K; wherein the particular filler is dispersed in a polymeric matrix comprising the reaction product of two silicone resins; wherein the thermally-conductive sheet exhibits a compression set of 1 to 10% and a compression force deflection of 1 to 20 psi;
wherein the compressible thermally-conductive sheet has a thermal conductivity that is at least 0.75 W/m-K;wherein the density of the through holes is 100,000 holes per square meter to 2 million holes per square meter; and wherein the non-foamed thermally conductive composition is free from filler particles comprising metal.
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25. A compressible thermally conductive sheet having a first and second heat transfer surface and a plurality of through holes substantially transverse to the first and second heat transfer surfaces to provide a thermal pathway there between;
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wherein said sheet comprises a foam polymeric pad having through holes that are filled with a non-foamed thermally conductive composition comprising about 20% to 80 by weight of dispersed thermally-conductive particulate boron nitride filler having on average a thermal conductivity of 25 to 500 W/m-K; wherein the particular filler is dispersed in a polymeric matrix comprising the reaction product of two silicone resins, wherein the cells of the polymeric foam pad have average cell diameters of about 20 to about 500 micrometer; wherein the thermally-conductive sheet exhibits a compression set of 1 to 10% and a compression force deflection of 1 to 20 psi; wherein the compressible thermally-conductive sheet has a thermal conductivity that is at least 0.75 W/m-K; wherein the density of the through holes is 100,000 holes per square meter to 2 million holes per square meter; and wherein the non-foamed thermally conductive composition is free from filler particles comprising metal.
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Specification