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. 2022 Oct;34(42):e2203939.
doi: 10.1002/adma.202203939. Epub 2022 Sep 20.

Thermoformable Boron Nitride Based All-Ceramics

Jason E Bice  1 , Echo St Germain  1 , Samuel J Wohlever  1 , Grace Goddard  1 , Randall M Erb  1
Affiliations

Thermoformable Boron Nitride Based All-Ceramics

Jason E Bice et al. Adv Mater. 2022 Oct.

Abstract

Thermoforming processing, traditionally reserved for thermoplastic polymers and sheet metals, is extended here to boron-based all-ceramics. Specifically, sintered boron nitride composite sheets manufactured via a combined vibration and tape-casting photopolymerization process exhibit a highly oriented microstructure that allows these preform sheets to flow as viscous Bingham pseudoplastics during compression molding. These sintered all-ceramic preforms are thermoformed into thin, complex parts with features down to 200 µm. Further, a new workflow is leveraged to generate bespoke all-ceramic heat spreaders that can be press-fit onto printed circuit boards and outperform metal heat sinks as a low-profile thermal management solution. This work offers a route for other all-ceramics that may be thermoformed through first fabricating pre-forms with highly-ordered anisotropic microstructures.

Keywords: boron-based ceramics; ceramic matrix composites; phononic heat transfer; thermal management; thermoforming.

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