Durable, Low-Cost, and Efficient Heat Spreader Design from Scrap Aramid Fibers and Hexagonal Boron Nitride

Aramid, chemically known as para phenylene terephthalamide or PPD-T, has been widely used in the reinforcement of telecommunication cables, rubber materials (transmission belts, pneumatic belts), ballistic clothing, and frictional materials primarily due to their high tensile resistance, high elastic modulus, and excellent thermal stability (−80–200 °C). These unique properties of aramid originate from its chemical structure, which consists of relatively rigid polymer chains linked by benzene rings and amide bonds (-CO-NH-). Here, in this work inspired by these properties, a heat spreader called Thermal Interface Material (TIM) is developed by synthesizing a resin from scrap aramid fibers. When hexagonal boron nitride (h-BN) as filler is introduced into the as-synthesized aramid resin to form a thin film of thermal sheet (50 μm), an in-plane thermal conductivity as high as 32.973 W/mK is achieved due to the firmly stacked and symmetric arrangement of the h-BN in the resin matrix. Moreover, the influence of h-BN platelet size is studied by fabricating thermal sheets with three different sizes of h-BN (6–7.5 μm, 15–21 μm, and 30–35 μm) in the aramid resin. The results of the study show that as platelet size increases, thermal conductivity increases significantly. Since the resin reported herein is developed out of scrap aramid fibers, the cost involved in the manufacture of the thermal sheet will be greatly lower. As the thermal sheet is designed with h-BN rather than graphene or carbonaceous materials, this high heat spreading sheet can be employed for 5G antenna modules where properties like a low dielectric constant and high electrical insulation are mandated.