Maya Ellison
Plastics are inherently thermal insulators, but they can be modified to improve their thermal conductivity. Thermally conductive plastics have been used to solve problems of heat build-up in electronics, appliances, lighting, automotive, and industrial products. The thermal conductivity of plastics can be increased by adding fillers such as silver, copper, CNTs, graphite, carbon black, or polymer fibres. The thermal conductivity of unfilled thermoplastics is typically around 0.2 W/mK, while thermally conductive plastic compounds can have 10 to 50 times higher conductivity (1-10 W/mK).
| Characteristics | Values |
|---|---|
| Thermal Conductivity of Plastics | Varies, with unfilled thermoplastics having a thermal conductivity of around 0.2 W/mK, and thermally conductive plastic compounds typically having 10 to 50 times higher conductivity (1-10 W/mK). |
| Thermal Conductivity Testing | The C-Therm Trident Thermal Conductivity Instrument, Modified Transient Plane Source (MTPS), Transient Plane Source (TPS), and Transient Line Source (TLS) are methods to test the thermal conductivity of plastics and polymers. |
| Thermally Conductive Plastics Applications | Used to solve problems of heat build-up in electronics, appliances, lighting, automotive, and industrial products. |
| Advantages | Lightweight, flexible, low-cost, and able to control heat build-up. |
| Heat-Conductive Additives | Graphite carbon fibers, ceramics such as aluminum nitride and boron nitride, and carbon-based fillers like graphite and carbon black. |
| Disadvantages | High initial cost. |
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What You'll Learn
- Plastic compounds can have 10 to 50 times higher thermal conductivity than unfilled thermoplastics
- Plastics can be modified to improve their thermal conductivity
- Thermally conductive plastics can help solve heat build-up issues in electronics
- Thermally conductive plastics can be used in fuel cells
- Graphite fibres are commonly used heat-conductive additives
Plastic compounds can have 10 to 50 times higher thermal conductivity than unfilled thermoplastics
Plastics are inherently thermal insulators, but modifying plastics to improve their thermal conductivity is an area of interest for many companies. Plastic compounds can have 10 to 50 times higher thermal conductivity than unfilled thermoplastics, which typically have a thermal conductivity of around 0.2 W/mK. This is achieved by adding fillers such as silver, copper, CNTs, carbon fibres, ceramics, and more, which increase the thermal conductivity of the plastic.
One company at the forefront of this field is Cool Polymers, whose products offer 100 to 500 times the conductivity of a base polymer (10-100 W/mK). They have demonstrated the benefits of their thermally conductive plastics through infrared photography, showing how their products can control heat build-up and generate a more isothermic profile. For example, their CoolPoly thermally conductive PP compound was shown to conduct heat away from a hot spot, resulting in a temperature difference of only 4° C throughout the panel, compared to a 24° C difference for a standard PP panel.
The use of thermally conductive plastics can provide cost savings of up to 30% compared to metal designs, making them a lightweight, flexible, and low-cost alternative. They are particularly suited to applications where heat-removal is a challenge, such as in electronics, appliances, lighting, automotive, and industrial products.
One example of a plastic compound with high thermal conductivity is Ensinger's TECACOMP HTE material, which has been developed for use in fuel cells. It achieves a high degree of electrical and thermal conductivity through a high filling ratio of graphite, carbon black, or polymer fibres, mixed with base polymers in a ratio of up to 90% by weight.
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Plastics can be modified to improve their thermal conductivity
Plastics are inherently thermal insulators. However, modifying plastics to improve their thermal conductivity is an emerging area of interest, particularly in addressing heat build-up issues in electronics, appliances, lighting, automotive, and industrial products.
The thermal conductivity of plastics can be enhanced through the use of fillers or additives. For instance, fillers such as silver, copper, carbon nanotubes (CNTs), graphite carbon fibers, ceramics (e.g., aluminum nitride and boron nitride), and other thermally conductive compounds can significantly increase the thermal conductivity of plastic composites. These fillers possess higher thermal conductivity than the base polymer, resulting in enhanced heat transfer capabilities.
One notable example is the development of thermally conductive Fortron PPS, which can withstand high temperatures during soldering and the operation of electronic equipment. This modified plastic has found applications in HVAC heat-exchanger side components and high-speed differential connectors.
Another pioneer in this field is Cool Polymers, which offers products with up to 500 times the conductivity of a base polymer (10-100 W/mK). They have demonstrated the superior performance of their thermally conductive PP compound through infrared photography. When compared to a standard PP panel, their compound effectively conducts heat away from a center hotspot, maintaining a more uniform temperature profile.
While the high initial cost of thermally conductive compounds remains a challenge for wider adoption, advancements in this field are crucial for improving the thermal management of various products, especially in the electronics industry, where the demand for efficient heat dissipation continues to grow.
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Thermally conductive plastics can help solve heat build-up issues in electronics
Plastics are used extensively in electrical systems and electronics. They are chosen for their unique thermal properties, such as their low melting point, which makes them easy to mould into various shapes. However, this can also be a disadvantage, as some plastics can deform or lose structural integrity when exposed to high temperatures.
Plastics are inherently poor conductors of heat, but this is changing. Thermally conductive plastics are being developed to solve heat build-up issues in electronics. These plastics have been modified to improve their thermal conductivity, which is around 10 to 50 times higher than that of unfilled thermoplastics. For example, Cool Polymers offers products with 100 to 500 times the conductivity of a base polymer.
The development of these plastics has been driven by the need to control heat build-up in ever-smaller and more power-hungry electronics. Thermally conductive plastics can provide lightweight, flexible, and low-cost solutions to heat management. They are particularly useful for small parts, as the injection moulding process is more cost-effective for smaller units.
A new technique developed by researchers at the University of Michigan uses a chemical process to expand and straighten the molecule chains in plastics, giving heat energy a more direct route through the material. This process also has the secondary benefit of stiffening the polymer chains, making them even more thermally conductive.
Thermally conductive plastics have a wide range of potential applications, including in electronics, appliances, lighting, automotive, and industrial products. For example, they can be used in HVAC heat-exchanger side components and high-speed differential connectors. They can also be used as heat sinks, replacing metals in the last few years.
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Thermally conductive plastics can be used in fuel cells
Plastics are typically not thermally conductive by nature. However, with the use of special additives, plastics can be optimized to exhibit high thermal conductivity, making them suitable for applications such as fuel cells.
Thermally conductive plastics are engineered materials that combine the heat transfer capabilities of metals with the lightweight and versatile properties of plastics. These plastics offer a unique solution for managing heat in various applications, including fuel cells.
In the context of fuel cells, thermally conductive plastics are particularly advantageous due to their ability to separate reaction gases and cooling media while distributing them efficiently in the reaction areas. This functionality is crucial for maintaining the long-term safe operation of fuel cells.
One notable example of thermally conductive plastics in fuel cells is the development of bipolar plates. Ensinger, in collaboration with the Center for Fuel Cell Technology (ZBT), has created innovative bipolar plates using graphitic thermoplastic materials. These plates offer numerous benefits, including efficient gas and coolant distribution, while also providing electrical and thermal optimization. The TECACOMP HTE compounds utilized in these plates are based on thermoplastic PP (polypropylene) and PPS (polyphenylene sulfide), making them suitable for a wide range of operating temperatures.
The use of thermally conductive plastics in fuel cells extends beyond bipolar plates. End plates, which form the anode and cathode terminations of the fuel cell stack, are also commonly made from thermoplastics. These end plates are designed to withstand high loads and meet the precise flatness requirements necessary for optimal fuel cell performance.
Thermally conductive plastics offer several advantages in fuel cell applications. They provide a lightweight alternative to metallic materials, reducing weight in electric vehicles and improving overall energy efficiency. Additionally, plastics can mitigate the issues of corrosion associated with metal plates, preventing the diffusion of metal ions into the electrolyte and maintaining conductivity and output voltage.
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Graphite fibres are commonly used heat-conductive additives
Plastics are inherently thermal insulators. However, modifying plastics to improve their thermal conductivity is an emerging area of opportunity for many companies. Thermally conductive plastics are used to solve problems of heat build-up in electronics, appliances, lighting, automotive, and industrial products.
Graphite fibres are used in applications where RFI shielding is required, such as handheld communication devices. They can also be used to form composites with other materials, such as graphite, to form reinforced carbon-carbon composites, which have a very high heat tolerance. These composites are used in aircraft and spacecraft parts, racing car bodies, golf club shafts, bicycle frames, and many other components where lightweight and high strength are needed.
Graphite fibres have a thermal conductivity of about 1,000 W/m.K in the axial direction of the fibre. Pitch-based graphite fibres have a modulus between 50 and 145 msi and are often used in space structures requiring high rigidity. The higher temperatures used in the graphitization process result in a closer orientation of the graphite crystallites towards the fibre axis, which increases the modulus of the fibre. However, high crystallinity also makes the fibre weak in shear, resulting in lower compressive strength.
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Frequently asked questions
Plastics are inherently thermal insulators, but some plastics have been modified to improve their thermal conductivity.
Thermal conductivity is the ability of a material to conduct heat. It is measured in Watts per meter-degree Kelvin (W/m-K).
The thermal conductivity of plastic can be increased by adding fillers such as silver, copper, carbon fibres, ceramics, and CNTs.
Plastics with high thermal conductivity are lightweight, flexible, and low-cost. They can be used to solve problems of heat build-up in electronics, appliances, lighting, automotive, and industrial products.
