Three-dimensional vertically aligned functionalized multilayer graphene

A method of making a thermal interface material for thermally coupling a heat source to a heat sink, comprising the steps of:

• (a) dispersing functionalized graphene sheets in a liquid;
• (b) removing the liquid through a filter so as to form a filtration cake of aligned functionalized graphene sheets, substantially all of which are parallel to a common plane;
• (c) cutting at least one block of aligned functionalized graphene sheets from the filtration cake, the block including a first end face and an oppositely-disposed second end face that are parallel to each other and to which substantially all of the functionalized graphene sheets are transverse, the block also including two oppositely-disposed sides to which substantially all of the functionalized graphene sheets are parallel;
• (d) applying a first stabilizing layer to the first end face and a second stabilizing layer to the second end face;
• and
• (e) placing the first stabilizing layer to be in thermal communication with the heat source and the second stabilizing layer to be in thermal communication with the heat sink.

A method of making a thermal interface material, comprising the steps of:

• (a) dispersing functionalized graphene sheets in a liquid;
• (b) removing the liquid through a filter so as to form a filtration cake of aligned functionalized graphene sheets, substantially all of which are parallel to a common plane, wherein the removing of the liquid is performed through a filtration process that includes the steps of:
• (i) disposing the functionalized graphene sheets dispersed in the liquid on a first side filtration paper;
• and
• (ii) applying a vacuum to a second side of the filtration paper, wherein the second side is opposite from the first side, so as to draw the liquid through the filtration paper and away from the functionalized graphene sheets;
• (c) cutting at least one block of aligned functionalized graphene sheets from the filtration cake, the block including a first end face and an oppositely-disposed second end face that are parallel to each other and to which substantially all of the functionalized graphene sheets are transverse, the block also including two oppositely-disposed sides to which substantially all of the functionalized graphene sheets are parallel;
• (d) applying a first layer of a thermally conductive substance to the first end face and applying a second layer of the thermally conductive substance to the second end face of the block;
• (e) aligning a group of blocks of aligned functionalized graphene sheets so that the first end face of each block is substantially coplanar with the first end face of each other block;
• (f) applying a common first layer of a thermally conductive substance to the first end face of each block;
• (g) applying a second common layer of the thermally conductive substance to the second end face of each block;
• (h) applying a first silicon layer to the first layer of the thermally conductive substance;
• and
• (i) applying a second silicon layer to the second layer of the thermally conductive substance.