skip to main content


Title: Liquid Metal Composites with Enhanced Thermal Conductivity and Stability Using Molecular Thermal Linker
Abstract

Gallium‐based liquid metal (LM) composite with metallic fillers is an emerging class of thermal interface materials (TIMs), which are widely applied in electronics and power systems to improve their performance. In situ alloying between gallium and many metallic fillers like copper and silver, however, leads to a deteriorated composite stability. This paper presents an interfacial engineering approach using 3‐chloropropyltriethoxysilane (CPTES) to serve as effective thermal linkers and diffusion barriers at the copper‐gallium oxide interfaces in the LM matrix, achieving an enhancement in both thermal conductivity and stability of the composite. By mixing LM with copper particles modified by CPTES, a thermal conductivity (κ) as high as 65.9 W m−1K−1is achieved. In addition, κ can be tuned by altering the terminal groups of silane molecules, demonstrating the flexibility of this approach. The potential use of such composite as a TIM is also shown in the heat dissipation of a computer central processing unit. While most studies on LM‐based composites enhance the material performance via direct mixing of various fillers, this work provides a different approach to fabricate high‐performance LM‐based composites and may further advance their applications in various areas including thermal management systems, flexible electronics, consumer electronics, and biomedical systems.

 
more » « less
NSF-PAR ID:
10446235
Author(s) / Creator(s):
 ;  ;  ;  ;  ;  
Publisher / Repository:
Wiley Blackwell (John Wiley & Sons)
Date Published:
Journal Name:
Advanced Materials
Volume:
33
Issue:
43
ISSN:
0935-9648
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
More Like this
  1. Abstract

    The thermal properties of epoxy‐based binary composites comprised of graphene and copper nanoparticles are reported. It is found that the “synergistic” filler effect, revealed as a strong enhancement of the thermal conductivity of composites with the size‐dissimilar fillers, has a well‐defined filler loading threshold. The thermal conductivity of composites with a moderate graphene concentration offg= 15 wt% exhibits an abrupt increase as the loading of copper nanoparticles approachesfCu≈ 40 wt%, followed by saturation. The effect is attributed to intercalation of spherical copper nanoparticles between the large graphene flakes, resulting in formation of the highly thermally conductive percolation network. In contrast, in composites with a high graphene concentration,fg= 40 wt%, the thermal conductivity increases linearly with addition of copper nanoparticles. A thermal conductivity of 13.5 ± 1.6 Wm−1K−1is achieved in composites with binary fillers offg= 40 wt% andfCu= 35 wt%. It has also been demonstrated that the thermal percolation can occur prior to electrical percolation even in composites with electrically conductive fillers. The obtained results shed light on the interaction between graphene fillers and copper nanoparticles in the composites and demonstrate potential of such hybrid epoxy composites for practical applications in thermal interface materials and adhesives.

     
    more » « less
  2. null (Ed.)
    Gallium based liquid metals (LM) have prospective biomedical, stretchable electronics, soft robotics, and energy storage applications, and are being widely adopted as thermal interface materials. The danger of gallium corroding most metals used in microelectronics requires the cumbersome addition of “barrier” layers or LM break-up into droplets within an inert matrix such as silicone oil. Such LM-in-oil emulsions are stabilized by native oxide on the droplets but have decreased thermal performance. Here we show that mixing of the silicone oil into an LM-air foam yields emulsions with inverted phases. We investigate the stability of these oil-in-LM emulsions through a range of processing times and oil viscosities, and characterize the impact of these parameters on the materials’ structure and thermal property relationships. We demonstrate that the emulsion with 40 vol% of 10 cSt silicone oil provides a unique thermal management material with a 10 W m −1 K −1 thermal conductivity and an exterior lubricant thin film that completely prevents corrosion of contacting aluminum. 
    more » « less
  3. Abstract

    Current stretchable conductors, often composed of elastomeric composites infused with rigid conductive fillers, suffer from limited stretchability and durability, and declined conductivity with stretching. These limitations hinder their potential applications as essential components such as interconnects, sensors, and actuators in stretchable electronics and soft machines. In this context, an innovative elastomeric composite that incorporates a 3D network of liquid metal (LM), offering exceptional stretchability, durability, and conductivity, is introduced. The mechanics model elucidates how the interconnected 3DLM architecture imparts softness and stretchability to the composites, allowing them to withstand tensile strains of up to 500% without rupture. The relatively low surface‐to‐volume ratio of the 3DLM network limits the reforming of the oxide layer during cyclic stretch, thereby contributing to low permanent strain and enhanced durability. Additionally, the 3D architecture facilitates crack blunting and stress delocalization, elevating fracture resistance, while simultaneously establishing continuous conductive pathways that result in high conductivity. Notably, the conductivity of the 3DLM composite increases with strain during substantial stretching, highlighting its strain‐enhanced conductivity. In comparison to other LM‐based composites featuring 0D LM droplets, the 3DLM composite stands out with superior properties.

     
    more » « less
  4. Abstract

    Composite materials with ordered microstructures often lead to enhanced functionalities that a single material can hardly achieve. Many biomaterials with unusual microstructures can be found in nature; among them, many possess anisotropic and even directional physical and chemical properties. With inspiration from nature, artificial composite materials can be rationally designed to achieve this anisotropic behavior with desired properties. Here, a metallic wood with metal continuously filling the wood vessels is developed, which demonstrates excellent anisotropic electrical, thermal, and mechanical properties. The well‐aligned metal rods are confined and separated by the wood vessels, which deliver directional electron transport parallel to the alignment direction. Thus, the novel metallic wood composite boasts an extraordinary anisotropic electrical conductivity (σ||) in the order of 1011, and anisotropic thermal conductivity (κ||) of 18. These values exceed the highest reported values in existing anisotropic composite materials. The anisotropic functionality of the metallic wood enables it to be used for thermal management applications, such as thermal insulation and thermal dissipation. The highly anisotropic metallic wood serves as an example for further anisotropic materials design; other composite materials with different biotemplates/hosts and fillers can achieve even higher anisotropic ratios, allowing them to be implemented in a variety of applications.

     
    more » « less
  5. Abstract

    The synthesis and characterization of epoxy‐based composites with few‐layer graphene fillers, which are capable of dual‐functional applications, are reported. It is found that composites with certain types of few‐layer graphene fillers reveal an efficient total electromagnetic interference shielding, SEtot≈ 45 dB, in the important X‐band frequency range,f= 8.2 −12.4 GHz, while simultaneously providing high thermal conductivity,K≈ 8 W m−1K−1, which is a factor of ×35 larger than that of the base matrix material. The efficiency of the dual‐functional application depends on the filler characteristics: thickness, lateral dimensions, aspect ratio, and concentration. Graphene loading fractions above the electrical and thermal “percolation thresholds” allow for strong enhancement of both the electromagnetic interference shielding and heat conduction properties. Interestingly, graphene composites can block the electromagnetic energy even below the electrical percolation threshold, remaining electrically insulating, which is an important feature for some types of thermal interface materials. The dual functionality of the graphene composites can substantially improve the electromagnetic shielding and thermal management of airborne systems while simultaneously reducing their weight and cost.

     
    more » « less