Thermal Modules Cost Reduction Through Innovative Processing of Annealed Pyrolytic Graphite (kTC P 215)

k Technology Corporation (kTC) produces high-conductivity (5x aluminum) thermal cores (k-Core TM) for passive cooling of electronic packages. The cores are made by encapsulating annealed pyrolytic graphite (APG) in aluminum. They are currently used in premium aerospace applications F22, F16, and military space platforms. By developing an innovative, targeted chemical vapor deposition (CVD) process specifically for thermal cores and related products, kTC plans to dramatically increase the yield of APG and subsequently significantly reduce the thermal core cost. The approach is to consider the total APG process (CVD, annealing, and machining) to develop the CVD parameters (flow rates, gas kinetics, mandrel design, gas flow paths, furnace run times) to produce high yields. Simplified gas dynamics and measured PG deposition data will be used to identify flow, mandrel shapes and deposition rates to produce uniform PG at optimum machinable thicknesses. A Preliminary Design of a CVD Deposition process system for high yield APG manufacture will be completed. Selected tests will be conducted to verify critical design assumptions. In Phase I of the program, the feasibility of the cost reduction process was demonstrated. In Phase II, kTC will develop and apply these concepts in a production context.