biostudies-literatureUnknown12(45)Yan DIn consideration of low density and high intrinsic thermal conductivity, spherical graphite powders can act as promising fillers for light weight thermal interface materials. Herein, spherical artificial graphite derived composites exhibit a similar thermal conductivity and significantly reduced bulk density compared with traditional Al₂O₃-derived composites. Further, based on the particle packing theory, an innovatively optimized calculation method has been proposed by introducing the quadratic programming method into the traditional calculation method to acquire the optimum formulation of multi-scale spherical graphite particles. The thermal conductivity of the optimum formulation-derived composites attains 1.994 W m^-1 K^-1, which is 1.72 times RSC advances29414-29422https://www.ebi.ac.uk/biostudies/studies/S-EPMC9558129biostudies-literatureMulti-scale hybrid spherical graphite composites: a light weight thermal interface material with high thermal conductivity and simple processing technology.PMC9558129Kong NLiu JLi ZYe CTian YHuang MYan DFu LWen BTan RHan FfalseMulti-scale hybrid spherical graphite composites: a light weight thermal interface material with high thermal conductivity and simple processing technology.In consideration of low density and high intrinsic thermal conductivity, spherical graphite powders can act as promising fillers for light weight thermal interface materials. Herein, spherical artificial graphite derived composites exhibit a similar thermal conductivity and significantly reduced bulk density compared with traditional Al₂O₃-derived composites. Further, based on the particle packing theory, an innovatively optimized calculation method has been proposed by introducing the quadratic programming method into the traditional calculation method to acquire the optimum formulation of multi-scale spherical graphite particles. The thermal conductivity of the optimum formulation-derived composites attains 1.994 W m^-1 K^-1, which is 1.72 times 2022-01-01T00:00:00Z2022 Oct2025-04-05T13:27:34.806Z2025-04-05T13:27:34.806ZS-EPMC95581293632074210.1039/d2ra04633d