Practical implementation of porous carbon-based composite phase-change materials (CPCMs) for heat dissipation in high-power-density electronics is usually limited by liquid leakage issues and unsatisfactory thermal conductivity resulting from their relatively low filler fraction and/or existence of interfacial thermal resistance between fillers. Therefore, development of shape-stable CPCMs with high thermal conductivity and large latent heat to avoid overheating of electronics remains challenging. Herein, graphene foams (GFs) with very high densities of up to 204 mg/ cm 3 have been synthesized to act as interconnected porous networks of CPCMs. Notably, the obtained CPCM with a filler loading of 11.1 wt % preserves a high heat capacity (171.8 J/g) with a retention of 84.8% while showing a 22.6-fold enhancement in the thermal conductivity as compared to pure PCM (10.13 vs 0.43 W/m•K). A higher thermal conductivity of 14.29 W/m•K can be achieved by further increasing the filler loading to 17.7 wt %, which outperforms many of the previously reported CPCMs based on the interconnected porous carbon-based frameworks. Owing to the superior interconnected network structure of the dense GFs and the strong interconnection between them and PCM molecules, these CPCMs also exhibit leakage-proof shape stability and excellent thermal reliability (at least 100 cycles). Moreover, a state-of-the-art aluminum (Al) package based on the CPCM (filler loading: 11.1 wt %) possessing weight 60% less than its pure Al panel counterpart has been demonstrated to verify better heat transfer efficiency and more efficient phonon pathways of the CPCM composite than those of the pure PCM, which holds great promise for advanced thermal management of emerging applications in electronics.
Construction of macroscopic 3D architectures of graphene is crucial to harness the advantageous properties of planar 2D graphene and to enable integration to many conventional and novel applications. Ideally, the 3D structure of graphene should be free of defects, covalently interconnected, and can be produced at large‐scale. Among various assembly techniques, fabrication using chemical vapor deposition (CVD) enables the production of high‐quality graphene where selection of template is the key that determines its consequent crystalline quality and structural morphology. Herein, a new method is presented to synthesize high‐quality porous graphene film by incorporating an in situ reduction–oxidation cycling treatment to generate micrometer‐sized pores on commercial Ni foil using an all‐CVD process route. Owing to the unique morphological features of the modified Ni template, the graphene film exhibits a holey surface with large‐area exterior skin coverage of >94% and many interconnected ligaments within its porous interior. This extraordinary configuration gives rise to superior in‐plane electrical conductivity despite its low density. In comparison to state‐of‐the‐art materials for electromagnetic interference shielding, this porous graphene film is among the best performing materials with a specific shielding effectiveness of >550 dB cm3 g−1 and absolute effectiveness of >220 000 dB cm2 g−1.
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