Millefeuille-Inspired Thermally Conductive Polymer Nanocomposites with Overlapping BN Nanosheets for Thermal Management Applications

Increasing power density makes modern electronic devices and power equipment generate excess heat, which greatly restricts the applications of polymeric materials because of their poor thermal conductivity. In the present work, inspired by the structure and production process of millefeuille cakes, we show that electrostatic spraying of boron nitride nanosheets (BNNSs) onto electrospun poly(vinyl alcohol) (PVA) nanofibers can produce highly thermally conductive, electrically insulating, flexible, and lightweight nanocomposites via a scalable method of building a multilayer PVA/BNNS nanonetwork structure. The PVA/BNNS nanocomposites exhibit an ultrahigh in-plane thermal conductivity of 21.4 W/(m·K) at 22.2 vol % BNNS addition, realized by an orientated BNNS network structure with overlapping interconnections. The BNNS networks exhibit low thermal resistance and interfacial heat scattering between BNNSs. Moreover, for heat dissipation applications, the nanocomposites with an overlapping BNNS network show higher efficiency in dissipating hot spots than randomly dispersed BNNS or directly hot-pressed BNNS composites. These PVA/BNNS nanocomposites can be used as high-performance lateral heat spreaders in next-generation thermal management systems.