Laminated graphene-based thermally conductive film and pad and method for manufacturing the film and pad

A method of manufacturing a laminated graphene-based thermally conductive film comprising vertically aligned graphene, the method comprising:

• providing a laminated film comprising a plurality of graphene film layers separated by an adhesive, the graphene film comprising graphene sheets aligned with the plane of the graphene film, wherein the plane of the graphene film is a first plane (XY) defined by a first axis (X) and a second axis (Y) perpendicular to the first axis;
• from the laminated film, forming a first heatsink structure having a base plate in a second plane (YZ) plane defined by the second axis (Y) and a third axis (Z) perpendicular to each of the first and second axis and a plurality of pillars extending in the direction of the first axis (X) with gaps between the pillars;
• from the laminated film, forming a second heatsink structure having a base plate in the second plane (YZ) defined by the second axis (Y) and the third axis (Z) perpendicular to each of the first and second axis and a plurality of pillars extending in the direction of the first axis (X), wherein the pillars of the second heatsink structure have a cross section and alignment corresponding to the gaps between pillars of the first heatsink structure;
• rotating the second heatsink structure about the first axis;
• joining the second heatsink structure to the first heatsink structure by means of an adhesive such that the pillars of the second heatsink structure fill the gaps between pillars of the first heatsink structure, and such that a rotational alignment of the first heatsink structure about the first axis is different from a rotational alignment of the second heatsink structure about the first axis;
• removing the base plates of the first and second heat sink structure, such that a block is formed consisting of a first plurality of sections having a first rotational alignment about the first axis (X) and a second plurality of sections having a second rotational alignment about the first axis (X), the second rotational alignment being different from the first rotational alignment;
• and
• cutting the block along a plane (Y′Z′) of the block defined by being perpendicular the first axis (X) to form a thermally conductive film having graphene sheets aligned perpendicularly to the plane (Y′Z′) of the thermally conductive film such that a first plurality of area portions of the thermally conductive film comprises graphene film having the first rotational alignment about the first axis (X), and a second plurality of area portions of the thermally conductive film comprises graphene film having the second rotational alignment about the first axis (X).