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<p>The surface of 45&#xa0;μm spherical Al<sub>2</sub>O<sub>3</sub> particles is converted to AlN through carbothermal reduction–nitridation (CRN) for use as a filler in thermal interface materials (TIMs). A numerical simulation is also conducted to demonstrate the effectiveness of Al<sub>2</sub>O<sub>3</sub> core/AlN shell-structured particles in enhancing thermal conductivity. The AlN conversion rate and microstructural evolution are analyzed as functions of CRN temperature, reaction time, N<sub>2</sub> pressure, carbon source, and nitridation promoter. Due to the volume change associated with transforming Al<sub>2</sub>O<sub>3</sub> to AlN via nucleation and growth, an air gap layer typically forms at the core/shell interface, which hinders thermal conduction. CRN performed at 1500–1600&#xa0;°C for 10–40&#xa0;h using a phenol resin results in a smooth AlN surface due to slow conversion kinetics; in contrast, more aggressive reaction conditions lead to disrupted particles with rough surfaces. TIM paste partially replaced with core/shell-structured particles exhibits at least a 20% improvement in thermal conductivity compared to TIM containing pure Al<sub>2</sub>O<sub>3</sub>.</p>

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Synthesis of 45 μm-sized Al2O3 core/AlN shell-structured spherical particles and numerical simulation for thermal interface materials application

  • 期刊论文

  • 发表日期：

    2025年8月8日

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  • Seong-Min Jang,
  • Yoon-Ki Byun,
  • Md Rokon Ud Dowla Biswas,
  • Byeongho Ahn,
  • Sung-Soo Ryu,
  • Dang-Hyok Yoon

摘要

The surface of 45 μm spherical Al2O3 particles is converted to AlN through carbothermal reduction–nitridation (CRN) for use as a filler in thermal interface materials (TIMs). A numerical simulation is also conducted to demonstrate the effectiveness of Al2O3 core/AlN shell-structured particles in enhancing thermal conductivity. The AlN conversion rate and microstructural evolution are analyzed as functions of CRN temperature, reaction time, N2 pressure, carbon source, and nitridation promoter. Due to the volume change associated with transforming Al2O3 to AlN via nucleation and growth, an air gap layer typically forms at the core/shell interface, which hinders thermal conduction. CRN performed at 1500–1600 °C for 10–40 h using a phenol resin results in a smooth AlN surface due to slow conversion kinetics; in contrast, more aggressive reaction conditions lead to disrupted particles with rough surfaces. TIM paste partially replaced with core/shell-structured particles exhibits at least a 20% improvement in thermal conductivity compared to TIM containing pure Al2O3.