Thermal Contact Conductance of Metal/Polymer Joints: An Analytical and Experimental Investigation

The heat e ow across a metal/polymer interface is a very important problem in many modern engineering applications. A thermal joint conductance model that employs the surface mechanics of a contact interface in conjunction with an existing elastic thermal contact conductance model was developed. In developing the model, an elastic contact hardness term was derived to predict the actual contact area of a metal/polymer interface under loading. The model predicts a microscopic resistance region where the interface resistance is dominant and a bulk resistance region where the thermal conductivity of the polymer is dominant. An experimental apparatus was fabricated, and a successful experimental program was conducted. New experimental data were gathered on different polymeric specimens over a pressure range of 138 ‐2758 kPa (20‐400 psi). The experimental data were compared to the proposed thermal joint conductance model. It was found that the proposed model predicted the data quite well. The data followed the predicted trends for both the microscopic and bulk resistance regions.