SBIR Phase I: High thermal conductivity continuous fiber reinforced 3D printing materials

SBIR第一期：高导热连续纤维增强3D打印材料

• 批准号: 1940285
• 负责人: Thomas Bougher
• 金额: $ 22.5万
• 依托单位: TCPoly
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2020
• 资助国家: 美国
• 起止时间: 2020-01-01 至 2020-12-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1940285&HistoricalAwards=false
• 关键词: SBIR; Phase; thermal; conductivity; continuous

The broader impact/commercial potential of this Small Business Innovation Research (SBIR) Phase I project is to develop thermally conductive 3D printing materials for cooling of high-performance electronic devices. As electronic devices become more compact and energy-dense, there is a growing challenge of overheating, resulting in poor performance and device failure. This problem is particularly relevant to transportation and energy-related technologies increasingly reliant on high-performance electronic components, such as electric motors, battery packs, power electronics, and high-performance processors. This project will develop a new additive manufacturing composite material with thermal conductivity 1000x higher than standard plastics, enabling lightweight, corrosion-resistant, and high-performance heat transfer technologies. Moreover, the materials enable 3D printing on low-cost desktop Fused Deposition Modeling printers without significant hardware modifications, drastically reducing the complexity and cost of printing high performance components. By creating a transformational material for use on a broadly accepted additive manufacturing technology platforms, this project will help create a new market for advanced heat transfer technologies that can significantly increase the performance of electronic devices.This Small Business Innovation Research (SBIR) Phase I project will result in the development of plastic composite materials with higher effective thermal conductivity than aluminum and the ability to be printed on low cost 3D printers. Thermally conductive plastic composites are traditionally composed of base polymer and a high content of thermally conductive filler particles, resulting in poor mechanical properties, high viscosity, high cost and processing difficulties (including inability to 3D print reliably), and a maximum thermal conductivity of ~30 W/m-K (nearly an order of magnitude lower than aluminum). Metals conduct heat well, but are heavy, expensive to manufacture into complex shapes, and can be susceptible to corrosion and fouling when interacting with fluids. This project is proposing a new composite system consisting of a core-shell structure with a core of continuous high thermal conductivity continuous fiber and a shell of a composite thermally conductive matrix. Utilizing 3D printing, this material can be printed into complex shapes to produce new heat transfer parts such as heat sinks, heat exchangers, liquid coldplates and other technologies with thermal performance exceeding metals.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

小型企业创新研究(SBIR)第一阶段项目的更广泛影响/商业潜力是开发用于高性能电子设备冷却的导热3D打印材料。随着电子设备变得更加紧凑和能源密集型，过热的挑战越来越大，导致性能低下和设备故障。这个问题与日益依赖高性能电子元件的交通和能源相关技术尤其相关，例如电动马达、电池组、电力电子和高性能处理器。该项目将开发一种新的添加剂制造复合材料，其导热系数比标准塑料高1000倍，从而实现轻质、耐腐蚀和高性能的热传递技术。此外，这些材料可以在低成本的台式熔融沉积建模打印机上进行3D打印，而无需进行重大的硬件修改，从而大大降低了打印高性能部件的复杂性和成本。通过创造一种用于广泛接受的添加剂制造技术平台的变革性材料，该项目将有助于为先进的热传递技术创造一个新的市场，这种技术可以显著提高电子设备的性能。这个小型企业创新研究(SBIR)第一阶段项目将导致开发具有比铝更高的有效导热系数的塑料复合材料，并能够在低成本的3D打印机上打印。导热塑料复合材料传统上由基础聚合物和高含量的导热填料颗粒组成，导致机械性能差、粘度高、成本高、加工困难(包括无法可靠地进行3D打印)，最大导热系数约为30W/m-K(几乎比铝低一个数量级)。金属导热性能良好，但重量较大，制造复杂形状的成本较高，而且在与流体相互作用时容易受到腐蚀和结垢。本项目提出了一种由连续高导热连续纤维芯壳结构和复合导热基质壳层组成的新型复合体系。利用3D打印，这种材料可以打印成复杂的形状，以生产新的热传递部件，如散热器、热交换器、液体冷板和其他热性能超过金属的技术。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势和更广泛的影响审查标准进行评估，被认为值得支持。