PMID- 33800734 OWN - NLM STAT- PubMed-not-MEDLINE LR - 20210408 IS - 2073-4360 (Electronic) IS - 2073-4360 (Linking) VI - 13 IP - 5 DP - 2021 Mar 6 TI - An Integrated Approach to Design and Develop High-Performance Polymer-Composite Thermal Interface Material. LID - 10.3390/polym13050807 [doi] LID - 807 AB - A computational framework based on novel differential effective medium approximation and mean-field homogenization is used to design high-performance filler-laden polymer thermal interface materials (TIMs). The proposed design strategy has the capability to handle non-dilute filler concentration in the polymer matrix. The effective thermal conductivity of intended thermal interface composites can be tailored in a wide range by varying filler attributes such as size, aspect ratio, orientation, as well as filler-matrix interface with an upper limit imposed by the shear modulus. Serval potential polymers and fillers are considered at the design stage. High-density polyethylene (HDPE) and thermoplastic polyurethane (TPU) with a non-dilute concentration (~60 vol%) of ceramic fillers exhibit high thermal conductivity (4-5 W m(-1) K(-1)) without compromising the high compliance of TIMs. The predicted thermal conductivity and coefficient of thermal expansion are in excellent agreement with measured data of various binary composite systems considering HDPE, TPU, and polypropylene (PP) loaded with Al(2)O(3) and AlN fillers in varying sizes, shapes, and concentrations, prepared via the melt-mixing and compression-molding route. The model also validates that manipulating filler alignment and aspect ratio can significantly contribute to making heat-conducting networks in composites, which results in ultra-high thermal conductivity. FAU - Akhtar, Syed Sohail AU - Akhtar SS AUID- ORCID: 0000-0002-7685-4681 AD - Mechanical Engineering Department, King Fahd University of Petroleum and Minerals (KFUPM), Dhahran 31261, Saudi Arabia. AD - Interdisciplinary Research Center for Intelligent Manufacturing and Robotics, KFUPM, Dhahran 31261, Saudi Arabia. AD - Center of Excellence in Nanotechnology, KFUPM, Dhahran 31261, Saudi Arabia. LA - eng PT - Journal Article DEP - 20210306 PL - Switzerland TA - Polymers (Basel) JT - Polymers JID - 101545357 PMC - PMC7962025 OTO - NOTNLM OT - composites OT - design OT - interface OT - polymer OT - thermal resistance COIS- The author declares no conflict of interest. EDAT- 2021/04/04 06:00 MHDA- 2021/04/04 06:01 PMCR- 2021/03/06 CRDT- 2021/04/03 01:06 PHST- 2021/02/12 00:00 [received] PHST- 2021/03/02 00:00 [revised] PHST- 2021/03/03 00:00 [accepted] PHST- 2021/04/03 01:06 [entrez] PHST- 2021/04/04 06:00 [pubmed] PHST- 2021/04/04 06:01 [medline] PHST- 2021/03/06 00:00 [pmc-release] AID - polym13050807 [pii] AID - polymers-13-00807 [pii] AID - 10.3390/polym13050807 [doi] PST - epublish SO - Polymers (Basel). 2021 Mar 6;13(5):807. doi: 10.3390/polym13050807.