Thermal paste is strictly necessary because air is a thermal insulator. Even when the bottom surface of a test section, such as a Triply Periodic Minimal Surface (TPMS) structure, appears flat, it contains microscopic imperfections. Without paste, these uneven areas create air pockets against the aluminum heating block, blocking heat flow and distorting your experimental data.
The presence of microscopic air gaps creates significant "contact thermal resistance." Thermal paste replaces this low-conductivity air with a high-conductivity medium, ensuring that measured temperatures accurately reflect the heat exchanger's true performance.
The Physics of Interface Imperfections
The Problem with "Flat" Surfaces
To the naked eye, the interface between a heat exchanger and a heating block seems seamless. However, at a microscopic level, these surfaces are rough terrain composed of peaks and valleys.
The Insulating Barrier
When two solid surfaces touch, they only make physical contact at the highest peaks of their surface roughness. The remaining space—often the majority of the interface area—is filled with air.
Why Air Must Be Eliminated
Air has extremely low thermal conductivity. These trapped air pockets act as a barrier, preventing heat from moving efficiently from the aluminum block to the test section.
The Function of Thermal Paste
Bridging the Gap
Thermal paste is engineered to be a viscous, high-conductivity material. Its primary function is to flow into the microscopic valleys of the surface texture.
Creating a Continuous Thermal Path
By displacing the air, the paste creates a continuous bridge between the heat source and the sink. This drastically reduces contact thermal resistance.
Ensuring Smooth Heat Transfer
With the air removed, heat transfer becomes smooth and efficient. The energy flows directly from the heating block into the TPMS structure without encountering significant resistance at the threshold.
The Impact on Experimental Accuracy
Reducing Measurement Errors
If you rely on surface-to-surface contact without paste, your temperature readings will be artificially high at the source and low at the sink. This creates a false delta that ruins experimental validity.
Reflecting True Dissipation Capacity
To evaluate a heat exchanger properly, you must measure the device's performance, not the inefficiency of the setup. Applying paste ensures that the surface temperature data reflects the actual heat dissipation capacity of the structure.
Common Pitfalls to Avoid
The "More is Better" Fallacy
While filling gaps is essential, applying too much paste creates a new problem. A thick layer of paste creates a physical distance between components, which adds its own thermal resistance.
Uneven Application
Inconsistent application can leave air pockets trapped in specific zones. This leads to localized hot spots and inconsistent data across the test section.
Ensuring Reliable Results
To maximize the accuracy of your thermal experiments, apply these principles:
- If your primary focus is data integrity: Apply thermal paste to ensure your measurements reflect the physics of the heat exchanger, not the flaws of the interface.
- If your primary focus is installation: Aim for the thinnest possible layer that still achieves 100% surface coverage to fill microscopic voids without adding bulk.
The goal is to replace a thermal insulator (air) with a thermal conductor, making the interface invisible to the heat flow.
Summary Table:
| Feature | Air Gaps (Dry Contact) | Thermal Paste Applied |
|---|---|---|
| Thermal Conductivity | Extremely Low (Insulator) | High (Conductor) |
| Interface Contact | Microscopic Peaks Only | Continuous Thermal Bridge |
| Thermal Resistance | High Contact Resistance | Minimized Resistance |
| Data Accuracy | Distorted (Artificial Deltas) | High (True Performance) |
| Heat Flow | Blocked/Inconsistent | Smooth & Efficient |
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References
- Gülenay Alevay Kılıç. Performance Evaluation of Triply Periodic Minimal Surface Heat Exchangers Using Nanofluids at High Flow Rates for Enhanced Energy Efficiency. DOI: 10.3390/app15084140
This article is also based on technical information from Kintek Press Knowledge Base .
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