Thermal Conductivity Enhancement Research Articles

Carbon fiber/boron nitride fillers for enhancing through-plane thermal conductivity of poly(vinylidene fluoride): Synergistic effect and mechanism

Two series of thermally conductive poly(vinylidene fluoride) (PVDF) composites were prepared by adding boron nitride (BN) and carbon fiber (CF) of different mass ratios via hot-pressing. The synergistic effects of the dual fillers on the thermal conductivity enhancement were investigated. The morphology, thermal conductivity, crystallinity, thermal stability, mechanical properties, and long-term chemical stability of the PVDF composites were characterized. The results demonstrated a significant synergistic effect between the BN and the CF on enhancing the thermal conductivity of the PVDF-based composites. The maximum thermal conductivity of 1.89 W/(m·K) with an improvement of 1014 % was achieved when 15 wt% BN and 15 wt% CF were added in the PVDF matrix. The synergistic effect resulted in the formation of efficient three-dimensional thermally conductive networks with a synergistic efficiency up to 113 %. The Agari model was employed to illustrate the thermal conduction mechanism, revealing the improved ability of the dual fillers to form conductive pathways. The PVDF composites showed good crystallinity, thermal stability, mechanical strength, and long-term chemical stability. This study highlights the potential of the PVDF/BN/CF composites for applications in membrane heat exchangers and provides significant insights into the design of high-performance thermally conductive polymer composites.

Self-assembled nest-like BN skeletons enable polymer composites with high thermal management capacity

The lagging development of thermally conductive but electrically insulating materials has become a bottleneck problem for the next generation of advanced high-power density electronic devices. Although second-phase reinforced composites are promising materials for addressing thermal management issues, the inherent mechanism of severe phonon scattering at the interphase results in actual thermal conductivity enhancement efficiency far below expectations. Here, we report a high-performance polymer composite with a nest-like interconnected boron nitride skeleton. This nest-like interconnected BN skeleton without mechanical contact can provide high-efficiency and long-distance phonon transport channel, realizing high thermal conductivity of 1.827 W m−1 K−1 in polymer composite with ultra-low content (4.7 vol%). Meanwhile, the EP/nest-like BS composites possess ideal electrical properties and dimensional stability. In the actual heat dissipation process of LED chips, the optimal composite material as the thermal interface material can display a temperature drop of more than 34.8 % compared to neat epoxy, which proves the broad application prospects of this strategy in advanced electronic devices.

Electrochemistry of Phase-Change Materials in Thermal Energy Storage Systems: A Critical Review of Green Transitions in Built Environments

This article reviews recent research on phase-change materials (PCMs) used in thermal energy storage systems with the aim of enhancing their performance. The study explores various methods to improve heat transfer in PCMs, such as microencapsulation, infill materials, fins and nanofluids. Additionally, it evaluates techniques to boost heat transfer in latent heat thermal energy storage (LHTES) systems and investigates ways to increase thermal conductivity using porous and low-density materials. PCMs store thermal energy, making them suitable for use in solar energy systems when solar energy is not available. The need for eco-friendly alternatives to conventional heating and cooling in global construction and the significant energy consumption of buildings has driven research on this topic. As such, this study additionally examines current advancements in free cooling systems with latent heat storage to identify the key factors affecting their effectiveness. The findings show that using PCMs for overnight cooling maintains the room temperature within the comfort zone and reduces the cooling loads in various climates. Using machine learning methods, this study also compares recent advancements in the use of PCMs in various solar energy systems, including solar thermal power plants, solar air purifiers, solar water heaters and solar appliances. Results derived feature key factors crucial for the optimal selection of PCMs and the challenges associated with sustainable green transitions in built environments. HIGHLIGHTS This review provides an in-depth examination of PCM thermal energy storage systems. This study investigates the use of fillers, nanofluids, and nanoparticles for enhanced heat transfer. Analytical methods for boosting the PCM thermal conductivity are briefly outlined. Geometric design and thermal conductivity enhancement affect the Latent Heat Thermal Energy Storage (LHTES). The assessment also evaluates advanced free-cooling systems using the LHTES. PCMs help to store heat energy in solar systems and bridge supply gaps. GRAPHICAL ABSTRACT

Achieving high-thermal-conductivity brazed joint between carbon-based composites and Mo-Cu alloys by increasing the heat transfer area

Carbon-fiber-reinforced carbon matrix (Cf/C)-Mo30Cu brazed joints play an important role in the cooling systems of thermonuclear reactors. However, the limited contact area of heterogeneous interfaces severely limits the heat transfer efficiency. To overcome this drawback, we prepare three-dimensional porous interfaces by pre-oxidizing the Cf/C composite. Results show that circular gaps are formed between the carbon fibers and the pyrolyzed carbon after pre-oxidization at 600 °C in air. Fster braze penetration in the Cf/C composite is achieved, and the heat-transfer area across the interface is dramatically increased. The room-temperature thermal conductivity of the joints reaches a maximum value of 146 W·m−1·K−1 at a pre-oxidation time of 2 min; this value is 30 % higher than that obtained without treatment. The enhancement in thermal conductivity is mainly attributed to the increased contact area at the interface between the brazing seam and the Cf/C matrix, which provides more channels for heat transfer. This method of significantly improving the thermal conductivity is an important guide for the thermal management of thermonuclear reactors.

Enhancing thermal conductivity of novel ternary nitrate salt mixtures for thermal energy storage (TES) fluid

Efficient thermal energy storage (TES) is crucial for concentrated solar power (CSP) plants, necessitating the exploration of advanced heat transfer fluids with enhanced thermal conductivity. Conventional binary nitrate salt mixtures have limitations in thermal performance, prompting research into ternary mixtures and nanoparticle additives. This study investigates novel ternary nitrate salt mixtures comprising potassium nitrate (KNO₃), lithium nitrate (LiNO₃), and magnesium nitrate hexahydrate (Mg(NO₃)₂·6 H₂O) as high-performance TES fluids during the during the heat absorption phase. Seven different salt compositions were synthesized and characterized using the laser flash technique to evaluate their thermal conductivity over 100–400°C. Results revealed a significant influence of composition on thermal conductivity, with maximum values during melting ranging from 0.0777 W/m·K to 0.7373 W/m·K. Melting points varied from 335 K to 340.39 K, demonstrating tailorability through compositional adjustments. Furthermore, incorporation of 0.5 wt% aluminum oxide (Al₂O₃) nanoparticles resulted in substantial thermal conductivity enhancements, with the most significant increase observed in TSF10 (from 0.0777 W/m·K to 0.491 W/m·K). These improvements are attributed to enhanced phonon transport, increased surface area, and Brownian motion facilitated by Al₂O₃ nanoparticles. The study provides a comprehensive cost analysis, including raw material costs, and discusses the potential efficiency gains for CSP applications. The findings contribute to the development of high-performance and cost-effective TES fluids, advancing the efficiency and viability of sustainable energy generation.

A wave-transparent electrothermal sandwich composite for high-efficient anti-icing/de-icing

Light-weight composite materials with multifunction are widely used on aircrafts, antennas and wind turbines. Its anti-icing/de-icing is still a great challenge due to its poor heat transmission and low heat resistance. To address these issues, a novel electrothermal sandwich composite (NESC) was prepared by hot pressing an electrothermal film into load-bearing composite materials. By optimizing the ingredient of boron nitride nanoparticle, the heat diffusion rate was improved by 86 %, saving ∼14 % of energy consumption for complete anti-icing in dynamic icing conditions compared to samples without thermal conductivity enhancement. Furthermore, high electromagnetic transmittance up to 80 % of NESC was ensured through electromagnetic design. Besides the high-efficient and electromagnetic compatible anti-icing performance, NESC also performs high resistance to acid/alkali, abrasion and impact, good heating uniformity, stable photothermal effect, and potential of large-area manufacture. This paper presents a promising solution for durable, multi-functional, compatible, and energy-saving composites for anti-icing and de-icing.

Thermal management performance of a novel elliptically grooved flat heat pipe system embedded with internally cooled condenser

Flat heat pipes (FHPs) with rectangular groove wick structures fail to sufficiently uplift the working fluid’s liquid meniscus to cover the upper sides of the groove walls due to the vertically flat wall design. This results in the formation of non-evaporative zones, particularly in the evaporator region, leading to elevated wall temperatures at high heat loads. To address this issue, a novel FHP with elliptical grooves as wick is designed and tested across heat loads ranging from 30 to 360 W. Elliptical groove depths of 0.5 mm and 0.7 mm are evaluated and compared to FHPs with rectangular grooves. Results showed that at 360 W, the 0.7 mm depth elliptical grooves resulted in 6.5 % reduction in evaporator wall temperature and 27.8 % reduction in thermal resistance, along with 31.5 % enhancement in effective thermal conductivity compared to rectangular grooves. The curvature of the elliptical grooves, combined with enhanced surface tension effects of the working fluid, efficiently uplifted the liquid meniscus to cover the upper wall of the groove, minimizing non-evaporative zones. Additionally, FHPs with elliptical grooves demonstrated lower entropy generation, indicating higher thermal efficiency. Consequently, FHPs with elliptical groove designs are concluded to be an efficient and suitable solution for the thermal management of miniaturized electronic devices.

Fabrication and building energy-saving performance evaluation of polyethylene glycol/polymethyl methacrylate/expanded graphite thermal enhanced shape-stable phase change material

Integrating Phase Change Material (PCM) with building envelope is a promising way to reduce building energy consumption. However, leakage and insufficient PCM loading rate for existing encapsulation strategies limit its further application. In this work, a safer and easier way to fabricate Shape-Stable Phase Change Material (SSPCM) is proposed, whose products combine the outstanding leakage-proof property and high PCM loading rate. With the method of in-situ polymerization, not only the Polyethylene Glycol (PEG) is packaged by Polymethyl Methacrylate (PMMA), but the Expanded Graphite (EG) also has a chance to be added as the property regulator. The prepared SSPCMs are proved to be shape-stable over melting temperature with a leakage rate under 1 %. The characterization test reveals that with EG mass fraction increase from 0 to 2.5 %, the thermal conductivity augments from 0.23 to 1.73 W/(m·K) while the phase change latent enthalpy changes from 85.11 kJ/kg to 116.10 kJ/kg. Notably, the EG is more than a thermal conductivity enhancer, it also plays an important role in the modification of comprehensive properties. To optimize the building energy-saving performance of SSPCMs, the factors affecting building cooling electricity consumption like deployment position and thermal properties are evaluated in detail. The simulation results show that the optimum strategy is employing SSPCM with 2.0 wt% EG in the middle of the envelope, the cooling electricity consumption can be reduced by 8.64 % compared with the benchmark. The physical mechanism of energy-saving is also discussed from multiple angles. From a statistical view, sensitivity and uncertainty analysis of the simulation results is completed, to identify the influence of input parameters and validate the reliability of the simulation results. Finally, an economic analysis is carried out, proving the economic feasibility for further application. This research provides valuable insights for SSPCM’s application and design of energy-efficient buildings.

PVA-assisted graphene aerogels composite phase change materials with anisotropic porous structure for thermal management

The rapid development of spacecraft thermal control systems necessitates high-performance phase change materials (PCMs) with low density, high thermal conductivity and high enthalpy. Graphene aerogels (GAs) prepared by unidirectional freezing are ideal candidates as thermal conductive networks for PCMs due to the anisotropic porous structures. However, constructing anisotropic thermal conductive composite PCMs with low graphene aerogel loading while employing environmentally friendly cross-linking agents remains challenging. To fulfill the research gap, this study explores the synthesis of poly(vinyl alcohol) (PVA)/graphene aerogels (PGAs) by hydrothermal reaction and conventional freeze-drying. Anisotropic PGAs with oriented porous structures were fabricated by unidirectional freezing. After annealing and impregnation with paraffin wax, composite PCMs with excellent shape stability were obtained. The prepared composite exhibits low density (0.82 g cm−3) and high enthalpy (165 J g−1). The combination of PVA and graphene enables the composite to achieve an ultralow graphene aerogel loading (0.85 wt%) while maintaining high thermal conductivity (1.37 W m−1 K−1), leading to a high specific thermal conductivity enhancement up to 477. This work sheds light on the potential of combing PVA and graphene to construct thermal conductive aerogels, intending to provide feasible means to develop high-performance PCMs for spacecraft thermal management.

Hydrogen-peroxide intercalated expanded graphite facilitates large enhancement in thermal conductivity of polyetherimide/graphite nanocomposites

In this work, we prepared expanded graphite (EG) filler using hydrogen peroxide (H2O2) as an oxidizing agent to study its impact on the thermal conductivity (k) of polyetherimide (PEI) composite, compared to EG prepared using sodium chlorate (NaClO3). Sulfuric acid was used as the primary intercalating agent for both synthesis routes. The use of H2O2 prepared EG (EG-H2O2) led to a remarkable ∼4030% enhancement (9.5 Wm−1K−1) in k of the PEI/EG composite, while the use of NaClO3 prepared EG (EG-NaClO3) led to a much smaller enhancement of ∼2190% (5.3 Wm−1K−1), at 10 wt% EG composition compared to kPEI (∼0.23 Wm−1K−1). Such findings exceed the current state-of-art in EG-based polymer composites. Detailed characterization was performed to understand the properties of EG-H2O2 and EG-NaClO3. Raman analysis revealed that H2O2 resulted in relatively defect-free EG (ID/IG ratio ∼0.04), thus preserving the k of graphite (∼2000 Wm−1K−1). Use of NaClO3, however, led to a large defect density (ID/IG ratio ∼0.25), yielding graphite with significantly diminished k. Furthermore, through-plane thermal diffusivity of EG-H2O2 paper was measured to be 9.5 mm2s-1 while that of NaClO3 case was measured to be 6.7 mm2s-1, thus directly confirming the beneficial impact of H2O2 in preserving the high k of graphene. X-ray photoelectron spectroscopy (XPS) revealed that the higher number of defects in EG-NaClO3 are due to the higher degree of oxidation induced by NaClO3. The results demonstrate the potential of EG-H₂O₂ as an efficient filler for achieving high thermal conductivity polymer composites.

Effectiveness of a PCM-based heat sink with partially filled metal foam for thermal management of electronics

Electronics often experience overheating, which occurs when insufficient or improper cooling causes temperatures to rise quickly, potentially leading to component failure. Recently, a passive technique utilizing phase change material (PCM)-based heat sinks is suitable for modern electronic cooling. However, due to its low thermal conductivity, Aluminum (Al) foam as a thermal conductivity enhancer (TCE) is used. In this study, a partial filling approach is employed, involving a heat sink designed to cool a protruding electronic component (EC) attached to a metal fin. The enthalpy-porosity method and the thermal equilibrium model are applied. Results show that the efficiency of the heat sink is improved by increasing the filling ratio of the Al foam, thereby reducing the EC temperature by 15.85 °C, shortness the melting time by more than 1000 s, and the overall effective conductivity enhanced by 25 times compared to the case without Al foam. In addition, the optimal partial filling ratio is determined to be 2/3, due to the considerable savings of 33.33 % in material cost and overall heat sink weight. The findings suggest that partial filling is a strategy that can be employed to achieve a more comprehensive performance in thermal management using PCM-based heat sinks.

Enhancing Thermal Conductivity of Phase Change Materials: A Review of Methods

Enhancing Thermal Conductivity of Phase Change Materials: A Review of Methods

Passive battery thermal management and thermal safety protection based on hydrated salt composite phase change materials

Lithium-ion batteries (LIBs) are progressing towards higher energy densities, extended lifespans, and improved safety. However, battery thermal management systems are facing increased demand owing to high-rate charging and discharging, dynamic operating conditions, and heightened thermal safety concerns. Therefore, this paper proposes a novel composite phase change material (CPCM) comprising Na2SO4-10H2O as the core phase change material (PCM) and expanded graphite as the thermal conductivity enhancer. The CPCM offers high latent heat, superior thermal conductivity, and a two-stage temperature control function for battery thermal management and safety. The optimal mass CPCM ratio, determined through comprehensive characterization and thermal property tests, resulted in a melting point of 29.05°C, latent heat of 183.7 J.g−1, and high thermal conductivity of 3.926 W.m−1.K−1. During normal LIB operations, the CPCM efficiently absorbs and transfers heat, reducing the peak LIB temperature from 66 to 34°C at 15°C ambient temperature during a 3.7C high-rate discharge. Under dynamic conditions, the peak temperatures across the three cycles were consistently controlled at 36.7, 36.4, and 35.8°C, respectively. In a thermal runaway state, the thermochemical heat storage of hydrated salt dehydration effectively slowed LIB temperature increase, delaying the time to reach 130°C by 187 s. Suppression of the temperature rise outside the CPCM, combined with an extended dehydration plateau of up to 320 s, prevented the occurrence and propagation of thermal runaway in the battery.

Casson hybrid nanofluid flow over a Riga plate for drug delivery applications with double diffusion

Abstract Casson fluid-mediated hybrid nanofluids are more effective at transferring heat than traditional heat transfer fluids in terms of thermal conductivity. Heat exchangers, cooling systems and other thermal management systems are ideal for use with Casson fluids. Precise control of the flow and release of medication is necessary when using Casson fluids in drug delivery systems because of their unique rheological properties. Nanotechnology involves the creation of nanoparticles that are loaded with drugs and distributed in Casson fluid-based carriers for targeted delivery. In this study, to create a hybrid nanofluid, both single-walled carbon nanotubes (SWCNTs) and multi-walled carbon nanotubes (MWCNTs) are dispersed in a Casson fluid with Fourier’s and Fick’s laws assumptions. The Casson fluid is suitable for various engineering and medical applications due to the enhancement of heat transfer and thermal conductivity by the carbon nanotubes. Our objective is to understand how SWCNTs and MWCNTs impact the flow field by studying the flow behavior of the Casson hybrid nanofluid when it is stretched against a Riga plate. The Darcy–Forchheimer model is also used to account for the impact of the porous medium near the stretching plate. Both linear and quadratic drag terms are taken into account in this model to accurately predict the flow behavior of the nanofluid. In addition, the homotopy analysis method is utilized to address the model problem. The outcomes are discussed and deliberated based on drug delivery applications. These findings shed valuable light on the flow characteristics of a Casson hybrid nanofluid comprising SWCNTs and MWCNTs. It is observed that the incorporation of carbon nanotubes makes the nanofluid a promising candidate for medical applications due to its improved heat transfer properties.

Enhancing electrical insulation and thermal conductivity in polydimethylsiloxane polymer nanocomposites through silica coating on carbon fibers

Mesophase pitch-based carbon fibers (MPCFs) exhibit high thermal conductivity (∼900Wm−1K−1) and are considered to be an important candidate for future thermal management. However, MPCFs lead to an increase in the electrical conductivity of nanocomposites due to the low volume electrical resistivity (∼10−3 Ω cm). The development of MPCFs nanocomposites with high thermal conductivity and good electrical insulation remains a challenging problem. In order to solve the problem, we utilized the surfactant cetyltrimethylammonium bromide (CTAB) as an anchor for hydrolysis, and employed a sol-gel method to deposit a silica coating on MPCFs (silica@MPCFs). Silica@MPCFs was used as the filler for polydimethylsiloxane (PDMS) matrix. The nanocomposites exhibit commendable thermal conductivity (achieving 1.52 Wm−1K−1) and excellent volume electrical insulation (exceeding 1013 Ω cm) at a 30 vol% concentration. Notably, both the thermal conductivity and volume electrical insulation exceed MPCFs/PDMS. This approach to electrical insulation treatment holds substantial potential for the future preparation of high-performance nanocomposites of electronic devices.

Enhancing thermal conductivity of AlN ceramics via vat photopolymerization through refractive index coupling and oxygen fixation

Despite the growing development of ceramic fabrication by vat photopolymerization (VP), major gaps remain in application. Particularly in the case of VP-printed aluminum nitride (AlN) ceramic, the thermal conductivity is still below 170 W·m−1·K−1, a critical benchmark for efficient heat dissipation. To address this challenge, here we prepared an AlN slurry with high curing thickness through RI coupling between liquid-solid phase, and took into account of the rheological property under high solid loading. Full dense AlN green bodies with solid loading up to 50 vol% were successfully printed. Aiming to to tackle the degradation of thermal conductivity issue caused by oxygen increment of AlN via VP, we systemically studied the form of oxygen in AlN preparation processes. Through the sintering optimization, the oxygen element from the hydrolysis of AlN surface was fixated in the sintering aid Y2O3. Eventually, without any special process control or additional treatment, the final sintered AlN ceramics prepared by the developed slurry present a full densification and the highest thermal conductivity (up to 187.9 W∙m−1∙K−1) of any known additive manufactured ceramics.

Interfacial bonding mechanism of graphene nanoplatelets reinforced AZ91D magnesium alloy prepared by semi-solid injection molding

The incompatibility between the strength and thermal conductivity of magnesium alloys limits their application in heat dissipation components. Magnesium matrix composites were obtained by adding reinforcements into the AZ91D alloy to achieve synergistic enhancement of mechanical and thermal conductivity to promote the application of magnesium alloy. Graphene nanoplatelets (GNPs) reinforced magnesium matrix composites were successfully prepared by semi-solid injection molding. The high viscosity of the semi-solid metal slurry contributes to the homogeneous dispersion of GNPs in the magnesium matrix. A GNPs/MgO/Mg heterostructure with high interfacial bonding strength was found at the interface of GNPs and α-Mg matrix. The semi-solid casting method improves the mechanical properties of the composites by grain refinement and simultaneously reduces the thermal conductivity. The addition of GNPs can balance the mechanical and thermal conductivity enhancement, and the most balanced properties of the composites are obtained when the content of GNPs is 0.3 wt%, with a tensile strength of 243.1 MPa, Vickers hardness of 93.7 HV, and thermal conductivity of 74.8 W/(m·K). Therefore, the semi-solid forming method is considered a promising processing method, and GNPs is considered an ideal reinforcement material to improve the performance of the magnesium matrix.

Significantly Promoting the Thermal Conductivity and Machinability of Negative Thermal Expansion Alloy via In Situ Precipitation of Copper Networks.

Rapid advancements in electronic devices yield an urgent demand for high-performance electronic packaging materials with high thermal conductivity, low thermal expansion, and great mechanical properties. However, it is a great challenge for current design philosophies to fulfill all the requirements simultaneously. Here, an effective strategy is proposed for significantly promoting the thermal conductivity and machinability of negative thermal expansion alloy (Zr,Nb)Fe2 through eutectic precipitation of copper networks. The eutectic dual-phase alloy exhibits an isotropic chips-matched thermal expansion coefficient and a thermal conductivity enhancement exceeding 200% compared with (Zr,Nb)Fe2, along with an ultimate compressive strength of 550MPa. The addition of copper reorganizes the composition of (Zr,Nb)Fe2, which smooths the magnetic transition and shifts it toward higher temperature, resulting in linear low thermal expansion in a wide temperature range. The highly fine eutectic copper lamellae construct high thermal conductivity networks within (Zr,Nb)Fe2, serving as highways for heat transfer electrons and phonons. The in situ forming of eutectic copper lamellae also facilitates the mechanical properties by enhancing interfacial bonding and bearing additional stress after yielding of (Zr,Nb)Fe2. This work provides a novel strategy for promoting thermal conductivity and mechanical properties of negative thermal expansion alloys via eutectic precipitation of copper networks.

Progress and perspective on thermal conductivity enhancement of phase change materials

Progress and perspective on thermal conductivity enhancement of phase change materials

Enhanced thermal conductivity and mechanical properties of boron nitride@polymethylacrylimide/epoxy composites with self-assembled stable three-dimensional network

Constructing a three-dimensional (3D) network of fillers with high thermal conductivity is considered to be an effective strategy to obtain ideal thermal management materials (TMM). However, 3D filler network is often disrupted by the subsequent processing and forming processes , and it is difficult to incorporate high levels of fillers into lyophilized aerogels, which is a key factor limiting their widespread use. In this work, boron nitride@polymethylacrylimide/epoxy (BN@PMI/EP) composites with a stable 3D BN network were prepared by freeze-drying and hot-pressing. A water-soluble copolymer quaternary ammonium salt has been synthesized by the solution polymerization. BN@PMI aerogel was obtained by the freeze-drying of ammonium salt and BN solution, and thermal imidization. BN@PMI aerogel has a six-membered imine ring structure that can be loaded with a high content of BN, which ensures the stability of the 3D BN network structure and facilitates the subsequent impregnation of EP in vacuum, which is one of the innovations of this work.The stable and complete 3D BN network leads to the enhancement of thermal conductivity, and the out-of-plane and in-plane thermal conductivities of BN@PMI/EP reach 1.21 W·m–1·K–1 and 2.76 W·m–1·K–1 at BN loading of 40% (mass), respectively. Meanwhile, the excellent mechanical properties and results of finite element simulation and actual experiments confirm that BN@PMI/EP is a potential TMM.