Improving the thermal, mechanical, and insulating characteristics of thermal interface materials with liquid metal-based diphase structure

Gallium-based liquid metal has significant research value in interfacial heat transfer due to high its thermal conductivity. However, its great fluidity frequently causes the risk of leakage and corrosion when in direct contact with heat sinks. In this paper, a high-performance thermal pad with diphase continuous structure reinforced by liquid metal is proposed. Nickel-coated copper particles connected by liquid metal ensure heat-transfer performance, while silicone rubber provides softness and strength. Utilizing the remarkable processability and insulation properties of conventional polymers, they function as a barrier layer to avoid liquid metal from overflowing. The findings indicate that the composite exhibits favorable insulation performance, mechanical characteristics, and a thermal conductivity of up to 12.41 W/(m K). Most notably, the problem of liquid metal overflow has been effectively resolved, rendering it highly applicable in the field of thermal management within the electronics industry.