Thermally conductive films play a crucial role in expanding the lifetime of electronics by dissipating concentrated heat to heatsinks. In this work, a thermally conductive film (g-TC film) was manufactured using a perforated graphite sheet (p-GS) and a UV-curable pressure-sensitive adhesive (PSA) by lamination. A novel UV-curable PSA was prepared by incorporating a UV-curable abietic acid ester into a PSA composition. The UV-curable PSA became a tack-free film upon UV irradiation; thus, a flexible g-TC film with a 52-μm thickness was obtained. The defects in the g-TC film caused by air bubbles were removed by treating the p-GS with oxygen plasma. As the UV-cured PSA made a joint through the holes in the p-GS, cleavage of the graphite was not observed after 10,000 U-folding test cycles with a folding radius of 1 mm. The calculated in-plane thermal conductivity of the fabricated g-TC film was 179 W∙m-1K-1, which was stable after the U-folding tests.
Keywords: U-folding test; UV-curable adhesive; perforated graphite sheet; thermally conductive film.