Simultaneous measurement of pressure-dependent bulk and interfacial thermal properties in thermal interface materials using square-pulsed source thermoreflectance

Abstract

Thermal interface materials (TIMs) critically regulate heat dissipation from electronic chips to heat spreaders, yet their thermal conductivity (k), volumetric heat capacity (C), and interfacial thermal resistance (ITR) evolve with mechanical pressure and cannot be determined simultaneously using existing steady-state or transient techniques. As a result, the coupled roles of bulk compaction and interfacial contact in governing heat transport in TIM assemblies remain poorly resolved. Here, we present a square-pulsed source (SPS) thermoreflectance method that enables simultaneous determination of k, C, and ITR in TIM stacks under controlled mechanical loading. By spanning square-wave modulation frequencies from 1 Hz to 10 MHz, SPS probes a broad range of thermal penetration depths, enabling distinction between heat diffusion in the TIM bulk and interfacial heat transfer at the Al/TIM contact. Measurements on a thermally conductive gel, a thermal pad, and a high-vacuum grease during compression-unloading cycles reveal distinct pressure-dependent thermal transport mechanisms. The gel and pad exhibit increases in k and C, reduced ITR, and pronounced hysteresis, indicating coupled bulk densification and persistent interfacial conformity during loading cycles. In contrast, the grease shows nearly pressure-independent bulk properties but a strong pressure dependence of ITR, consistent with an interface-dominated response. These results resolve the long-standing challenge of simultaneously quantifying bulk and interfacial thermal transport in mechanically loaded TIM assemblies, enabling experimentally constrained thermal management and reliability analysis in electronic packaging.