The continued miniaturization and proliferation of electronics is met with significant thermal management challenges. Decreased size, increased power densities, and diverse operating environments challenge the limitations of conventional thermal management schemes and materials. To enable the continuation of these trends thermal interface materials (TIMs) that are used to enhance heat conduction and provide stress relief between adjacent layers in a electronic package must be improved. Forests comprised of nominally vertically aligned carbon nanotubes (CNTs), having outstanding thermal and mechanical properties, are excellent candidates for next-generation thermal interface materials (TIMs). However, despite nearly a decade of research, TIMs based on vertically aligned CNT forests have yet to harness effectively the high thermal conductivity of individual CNTs. One of the key obstacles that has limited the performance of CNT TIMs is the presence of high thermal contact resistances between the CNT free ends and the surfaces comprising the interface. The aim of this research is to better understand the mechanisms by which the thermal contact resistance of CNT forest thermal interfaces can be reduced and to use this understanding towards the design of effective and to scalable processing methods. Contact area and weak bonding between the CNT tips and opposing surface are identified as factors that contribute significantly to the thermal contact resistance. Three strategies are explored that utilize these mechanisms as instruments for reducing the contact resistance; i) liquid softening, ii) bonding with surface modifiers, and iii) bonding with nanoscale polymer coatings. All three strategies are found to reduce the thermal contact resistance at the CNT forest tips to below 1 mm2-K/W, a value to where it is no longer the factor limiting heat conduction in CNT forest TIMs. These strategies are also relatively low-cost and amenable to scaling for production when compared to existing metal-based bonding strategies.

To allow electronic devices to operate within allowable temperatures, heat sinks and fans are employed to cool down computer chips. However, cooling performance is limited by air gaps between the computer chip and the heat sink, due to the fact that air is a poor heat conductor. To alleviate this problem, thermal interface material (TIM) is often applied between mating substrates to fill air gaps. Carbon nanotube (CNT) based TIM has been reported to have excellent thermal impedance; however, because it is non biodegradable, its potential impact on the environment is a concern. In this thesis research, two types of TIMs were designed, synthesized, and characterized. The first type, Designed TIM 1, consisted of anodic aluminum oxide (AAO) templates with nanochannels (pore size=80nm) embedded with copper nanowires by electrodeposition. This type of nanostructure was expected to have low thermal impedance because the forest-like structure of copper nanowires can bridge two mating surfaces and efficiently transport heat one dimensionally from one substrate to the other. The second type, Designed TIM 2, was fabricated by sandwiching Designed TIM 1 with commercially available thermal grease to further reduce thermal impedance. It was expected that the copper nanowire structures would secure the thermal grease in place, thus preventing grease pump-out under contact pressure, which is a common problem associated with the usage of thermal grease. The morphologies of the two designed TIMs were studied using scanning electron microscopy (SEM), and their thermal properties were determined using ASTM D5470-06, the standard method for testing thermal transmission properties of thermally conductive materials. Experiments were conducted to evaluate the proposed TIMs, as well as commercially available TIMs, under different temperature and pressure settings. Experimental results suggest that the thermal impedance of TIMs can be reduced by increasing contact pressure or reducing thickness. Designed TIM 2 yielded 0.255℃-cm2/W, which is lower than thermal grease and other available TIMs at the operating temperature of 50 to 60℃. Considering the application limitations and safety issues of thermal grease, phase change material, and CNT-based TIMs, our designed TIMs are safe and promising for future applications.

Polymer nanocomposites are used in a variety of applications due to their good mechanical properties. Specifically, better performance of lithium ion batteries and thermal interface material can be obtained by using conductive materials and polymer composites. In the case of lithium ion batteries, electrochemical properties of batteries can be improved by adding conductive additives and conducting polymer into the cathode. Several samples, to which different conductive additives and conducting polymer were added, were prepared and their electrical resistance and discharge capacity measured. In the thermal interface material case, also, thermal properties can be enhanced by polymer nanocomposites. In order to confirm the thermal conductivity enhancement, samples were synthesized using different filler, polymer and methods, and their thermal conductivity measured. The influence of polymer nanocomposites and results are discussed and future plan are presented. In addition, reasons of thermal conductivity changing in each case are discussed.

<p dir="ltr">This work investigates four aspects of Ga-based low melting temperature alloys in their role as TIMs: the interaction between Ga and metal substrates, the change in the thermodynamic behavior of the liquid metal alloy, the evolution of the thermal performance, and mitigation strategies against Ga corrosion.</p>

We design a facile approach to investigate the role benzene derivatives play in the capacitance enhancement of graphene-based supercapacitors. The main reason is attributed to the pseudocapacitance of the aromatic molecules rather than the former one. Meanwhile, we find that the para and ortho substituted benzene derivatives contribute much more than the meta substituted ones. In addition, we fabricate an all-solid-state flexible MSC based on metal-reduced GO. The as-fabricated MSC shows high areal capacitance and excellent reliability, which makes it a promising energy storage candidate for wearable electronics. Based on the work of MSC, we achieve a flexible ac line-filter that is not only competitive against commercial product but also suitable for mass production. Meanwhile, we produce a three-dimensional graphene/polydimethylsiloxane composite that gives a thermal resistance as small as 14 mm2K/W, which is comparable to commercial products. What’s more, a convenient transient program that saves much time is developed to measure the thermal resistance.

abstract: Advancements in thermal interface materials (TIMs) allows for the creation of new and more powerful electronics as they increase the heat transfer from the component to the heat sink. Current industrial options provide decent heat transfer, but the creation of TIMs with higher thermal conductivities is needed. In addition, if these TIMs are elastic in nature, their effectiveness can greatly increase as they can deal with changing interfaces without degradation of their properties. The research performed delves into this idea, creating elastic TIMs using liquid metal (LM), in this case galinstan, along with other matrix particles embedded in Polydimethylsiloxane (PDMS) to create an easy to use, relatively inexpensive, thermally conductive, but electrically insulative, pad with increased thermal conductivity from industrial solutions. The pads were created using varying amounts of LM and matrix materials ranging from copper microspheres to diamond powder mixed into PDMS using a high-speed mixer. The material was then cast into molds and cured to create the pads. Once the pads were created, the difficulty came in quantifying their thermal properties. A stepped bar apparatus (SBA) following ASTM D5470 was created to measure the thermal resistance of the pads but it was determined that thermal conductivity was a more usable metric of the pads’ performance. This meant that the pad’s in-situ thickness was needed during testing, prompting the installation of a linear encoder to measure the thickness. The design and analysis of the necessary modification and proposed future design is further detailed in the following paper. / Dissertation/Thesis / Masters Thesis Mechanical Engineering 2017

Effective application of thermal interface materials (TIM) sandwiched between silicon and a heat spreader in a microelectronic package for improved heat dissipation is studied through thermal and mechanical characterization of high thermally conductive carbon nanotubes (CNTs) integrated into eutectic gallium indium liquid metal (LM) wetting matrix. Thermal conductivity data from Infrared microscopy tool reveals the dependence of experimental factors such as matrix types, TIM contacting interfaces, orientation of CNTs and wetting of CNTs in the matrix on the thermal behavior of TIM composite. Observed generalized trend on LM-CNT TIM shows progressive decrease in effective thermal conductivity with increasing CNT volume fractions. Further thermal characterizations LM-CNT TIM however show over 2x increase in effective thermal conductivity over conventional polymer TIMs (i.e. TIM from silicone oil matrix) but fails to meet 10x improvement expected. Poor wetting of CNT with LM matrix is hypothesized to hinder thermal improvement of LM-CNT TIM composite. Thus, wetting enhancement technique through electro-wetting and liquid crystal (LC) based matrix proposed to enhance CNT-CNT contact in LM-CNT TIM results in thermal conductivity improvement of 40 to 50% with introduction of voltage gradient of 2 to 24 volts on LM-CNT TIM sample with 0.1 to 1 percent CNT volume fractions over non voltage LM-CNT TIM test samples. Key findings through this study show that voltage tests on LC- CNT TIM can cause increased CNT-CNT networks resulting in 5x increase in thermal conductivity over non voltage LC-CNT TIM and over 2x improvement over silicone-CNT TIMs. Validation of LM wetting of CNT hypothesis further shows that wetting and interface adhesion mechanisms are not the only factors required to improve thermal performance of LM-CNT TIM. Anisotropic characteristic of thermal conductivity of randomly dispersed CNTs is a major factor causing lower thermal performance of LM-CNTs TIM composite. Other factors resulting in LM-CNT TIM decreasing thermal conductivity with increasing CNT loading are (i) Lack of CNT-CNT network due to large difference in surface tension and mass density between CNTs and LM in TIM composite (ii) Structural stability of MWCNT and small MFP of phonons in ~5um MWCNTs compared to the system resulted in phonon scattering with reduced heat flow (iii) CNT percolation threshold limit not reached owing to thermal shielding due to CNT tube interfacial thermal resistance. While mixture analytical models employed are able to predict thermal behaviors consistent with CNT-CNT network and CNT- polymer matrix contact phenomenon, these models are not equipped to predict thermo-chemical attributes of CNTs in LM-CNT TIM. Extent of LM-CNT wetting and LM-solid surface interfacial contact impacts on interfacial thermal resistance are investigated through LM contact angle, XPS/AES and SEM-EDX analyses on Au/Ni and Ni coated copper surfaces. Contact angle measurements in the range of 120o at both 55oC and 125oC show non wetting of LM on CNT, Au and Ni surfaces. Interface reactive wetting elemental composition of 21 days aged LM on Au/Ni and Ni surfaces reveals Ga dissolution in Au and Ni diffusion of ~0.32um in Au which are not present for similar analysis of 1 day LM on Au/Ni surface. Formation of Au-Ni-Ga IMC and IMC-oxide iono-covalency occurrence at the interface causes reduction in surface tension and reduction in interfacial contact resistance.

Lighting technologies have evolved over the years to become higher quality, more efficient sources of light. LEDs are poised to become the market standard for general lighting because they are the most power efficient form of lighting and do not contain hazardous materials. Unfortunately, LEDs pose unique problems because advanced thermal management is required to remove the high heat fluxes generated by such relatively small devices. These problems have already been overcome with complex packaging and exotic materials, but high costs are preventing this technology from displacing current lighting technologies. The purpose of this study is to develop a low-cost LED lighting package capable of successfully managing heat. Several designs were created and analyzed based on cost, thermal performance, ease of manufacturing, and reliability. A unique design was created which meet these requirements. This design was eventually assembled as a prototype and initial testing was conducted. This thesis reviews the design process and eventual results of the LED package design.

Since most of the energy input is converted to thermal energy in laser applications, the proper thermal management of laser systems is an important issue. Maintaining the laser diode and crystal temperature distributions in a narrow range during the operation is the most crucial requirement for the cooling of a laser system. In the present study, thermoelectric cooling (TEC) of a 1064 nm wavelength diode pumped laser source is investigated both experimentally and numerically. During the heat removal process, the thermal resistance through and between the materials, the proper integration of the TEC assembly, and the heat sink efficiency become important. For the aim of evaluating and further improving the system performance, various assembly configurations, highly conductive components, efficient interface materials and heat sink alternatives are considered. Several experiments are conducted during the system development stage, and parallel numerical simulations are performed both for comparison and also for providing valuable input for the system design. Results of the experiments and the simulations agree well with each other. As the laser device works in the transient regime, the experiments and the simulations are also implemented in this regime. In the final part of the study, the experiments are performed under the actual device working conditions. It is proved that with the designed TEC module and the copper heat sink system, the laser device can operate longer than the required operational time successfully.

The development of wide band gap semiconductors for power and RF electronics as well as high power silicon microelectronics has pushed the need for advanced thermal management techniques to ensure device reliability. While many techniques to remove large heat fluxes from devices have been developed, fewer advancements have been made in the development of new materials which can be integrated into the packaging architecture. This is especially true in the development of thermal interface materials. Conventional solders are currently being used for interface materials in the most demanding applications, but have issues of high cost, long term reliability and inducing negative thermomechanical effects in active die. Carbon nanotubes have been suggested as a possible thermal interface material which can challenge solders because of their good thermal properties and 1-D structure which can enhance mechanical compliance between surfaces. In this work, we have developed a novel growth and transfer printing method to manufacture vertically aligned CNTs for thermal interface applications. This method follows the nanomaterial transfer printing methods pioneered at Georgia Tech over the past several years. This process is attractive as it separates the high growth synthesis temperatures from the lower temperatures needed during device integration. For this thesis, CNTs were grown on oxidized Si substrates which allowed us to produce high quality vertically aligned CNTs with specific lengths. Through the development of a water vapor assisted etch process, which takes place immediately after CNT synthesis, control over the adhesion of the nanotubes to the growth surface was achieved. By controlling the adhesion we demonstrated the capability to transfer arrays of vertically aligned CNTs to polyimide tape. The CNTs were then printed onto substrates like Si and Cu using a unique gold bonding process. The thermal resistances of the CNTs and the bonded interfaces were measured using the photoacoustic method, and the strength of the CNT interface was measured through tensile tests. Finally, the heat dissipation capabilities of the vertically aligned CNTs were demonstrated through incorporation with high brightness LEDs. A comparison of LED junction temperatures for devices using a CNT and lead free solder thermal interface was made.