Thermal Fillers Enable Next-Gen Thermal Management for Electric Vehicles

High power high frequency transmission devices are being used extensively to enable faster data transmission and smarter function in many applications, such as automotive radar sensors, 5G telecommunication devices and infrastructures.
Higher power, faster data transmission, lighter weight, and smaller size are desired by today’s and next generation’s high performance high frequency devices. These demands lead to increasing concerns about the dissipation of significantly increased heat and the prevention of transmission loss. 
Thermally conductive dielectric polymer composites with high dielectric strength and low dielectric constant were widely used as thermal management materials in these electronic devices to enable fast heat dissipation while achieving excellent electrical insulation and low signal loss at high frequency.
As these dielectric polymers are naturally thermal insulative, ceramic thermal fillers must be added to the polymer matrix during the compounding process to improve bulk thermal conductivity while maintaining electric resistance. Dielectric properties of ceramic thermal fillers play a critical role in maintaining the high dielectric strength and low dielectric constant of filled polymer composites. 

As illustrated in the table below, among all the typical ceramic thermal fillers used in developing dielectric thermally conductive polymer composites, high purity crystalline hexagonal boron nitride (h-BN) and silica are the only two ceramic fillers with dielectric constants <4. Therefore, both have been popular as thermal fillers in polymer based thermal management materials for high frequency applications. The enhanced performance (power) and higher integration density of next generation high frequency devices inevitably drive up the power density which results in substantially increased heat to be dissipated within shrinking space. High purity h-BN powder, which has the highest thermal conductivity, highest electric resistivity, and lowest hardness, now has been the most attractive thermal fillers for high performance thermal management materials used in high frequency environment.

TYPICAL PROPERTIES BN AIN AI2O3 SiO2 ZnO
Thermal Conductivty (W/m-K)
300*
260
30
1.4
54
Specific Heat (J/kg-K @ 25°C)
800
730
800
690
520
Theoretical Density (g/cc)
2.2
3.2
4.0
2.2
5.6
Dielectric Constant
3.9
8.8
9.7
3.8
9.9
Volume Resistivity (ohm-cm)
1015
1014
1014
1014
1014
Coefficient of Thermal Expansion (ppm/K)
<1
4.4
6.7
<1
<1
Mohs Hardness
2
7
9
6
5

* Thermal conductivity in crystal plane

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