Preparation of Thermally Conductive Silicone Rubber-Based Ultra-Thin Sheets with Low Thermal Resistance and High Mechanical Properties

Abstract

Thermally conductive silicone rubber (TCSR)-based thin sheets with low thermal resistance and high electrical insulation properties have been widely used in thermal management applications in the electronic and energy storage fields. The low thermal resistance is mainly attributed to the sheets’ small thickness. In order to further decrease the sheets’ thermal resistance, it is necessary to decrease their thickness. However, the sheets mostly have a thickness of at least 0.20 mm, and it is still a challenge to decrease the thickness to less than 0.10 mm mainly due to the difficulty of smooth calendering through a narrow roll-to-roll gap on calenders. Here, a low-viscosity calendering method has been developed to prepare TCSR-based ultra-thin sheets. The sheets present unprecedentedly small thickness (~0.08 mm), low thermal resistance (0.87 cm2K/W), high tensile strength (~8 MPa), high flexibility, high electrical resistance (>1014 Ω·cm), and high thermal dissipation (>30 °C decrease in LED working temperature). Comparison studies between this new method and the conventional preparation method have been carried out to understand the mechanism of the improvements.