Flexible Graphite Thermal Management Devices

Abstract

The invention provides to thermal management devices constructed from flexible graphite. In one embodiment, the thermal management device includes a wick structure inside a shell. In certain preferred embodiments, the wick structure is composed of a mass of expanded graphite. In a another embodiment, the shell of the device includes flexible graphite and an optional wick structure. In certain preferred embodiments, the flexible graphite shell is fluid impermeable. The invention further includes methods of making the aforementioned thermal management devices.

1 . A thermal management device comprising:
 a. a substantially fluid impermeable shell having an evaporator portion and a condenser portion;   b. a wick structure inside said shell, said wick structure comprising a mass of expanded graphite;   c. a working fluid circulating inside said shell; and   d. the substantially fluid impermeable shell having a mating element disposed at its evaporator portion, wherein the mating element comprises at least one sheet of compressed particles of exfoliated graphite.   
     
     
         2 . (canceled) 
     
     
         3 . The thermal management device according to  claim 1  wherein said sheet of compressed particles of exfoliated graphite which forms said mating element comprises at least one resin impregnated sheet of compressed particles of exfoliated graphite. 
     
     
         4 - 20 . (canceled) 
     
     
         21 . The thermal management device of  claim 1  wherein the mating element comprises at least one sheet of compressed particles of exfoliated graphite having a density of at least about 1.1 g/cc. 
     
     
         22 . The thermal management device of  claim 21 , wherein the at least one sheet of compressed particles of exfoliated graphite has a density of at least about 1.6 g/cc. 
     
     
         23 . The thermal management device of  claim 21 , wherein the in-plane thermal conductivity of the at least one sheet of compressed particles of exfoliated graphite is at least about 400 W/m-K. 
     
     
         24 . The thermal management device of  claim 3 , wherein the at least one sheet of compressed particles of exfoliated graphite is impregnated with about 5% resin by weight. 
     
     
         25 . A thermal management device comprising:
 a. a substantially fluid impermeable shell having an evaporator portion and a condenser portion;   b. a working fluid circulating inside said shell; and   c. the substantially fluid impermeable shell having a dissipation fin disposed at its condenser portion, wherein the dissipation fin each comprise at least one sheet of compressed particles of exfoliated graphite.   
     
     
         26 . The thermal management device according to  claim 25  wherein said sheet of compressed particles of exfoliated graphite which forms said dissipation fin comprises at least one resin impregnated sheet of compressed particles of exfoliated graphite. 
     
     
         27 . The thermal management device of  claim 26 , wherein the at least one sheet of compressed particles of exfoliated graphite is impregnated with about 5% resin by weight. 
     
     
         28 . The thermal management device of  claim 25  wherein the at least one sheet of compressed particles of exfoliated graphite having a density of at least about 1.1 g/cc. 
     
     
         29 . The thermal management device of  claim 28 , wherein the at least one sheet of compressed particles of exfoliated graphite has a density of at least about 1.6 g/cc. 
     
     
         30 . The thermal management device of  claim 28 , wherein the in-plane thermal conductivity of the at least one sheet of compressed particles of exfoliated graphite is at least about 400 W/m-K.