Synergistic alumina particles and low-magnetic-field-induced vertical carbon fiber arrays for enhanced thermal conductivity and resilience of thermal interface materials

Abstract

Currently, advanced thermal interface materials (TIMs) with both high thermal conductivity and elasticity are required to meet the heat dissipation needs of cutting-edge electronic devices. Therefore, constructing an ordered thermal conductive structure without compromising mechanical resilience is an attractive strategy for developing advanced TIMs. Herein, we propose a promising orientation strategy based on the synergistic interaction of magnetic fields and gravity to construct a tightly packed vertical CFs arrays within the silicone rubber (SR) matrix, where the alignment of CFs along the magnetic field is assisted by gravity. Furthermore, by incorporating spherical alumina particles to bridge the inter-fiber gaps while maintaining the integrity of CFs arrays, a defect-minimized thermal network has been created to significantly enhance both the thermal conductivity and mechanical properties of the composites. The prepared composite possesses a superior thermal conductivity of 30.8 W m⁻¹ K⁻¹, a low hardness of Shore 00 53, and an outstanding compressibility of 42.3 % under 40 psi. This work establishes a paradigm-shifting strategy for scalable production of next-generation TIMs, offering a robust solution to solve thermal management challenges in high-power electronics, optoelectronics, and energy storage systems.