We present a switchable thermal interface based on an array of discrete liquid droplets initially confined on hydrophilic islands on a substrate. The droplets undergo reversible morphological transition into a continuous liquid film when they are mechanically compressed by an opposing substrate to create low-thermal resistance heat conduction path. We investigate a criterion for reversible switching in terms of hydrophilic pattern size and liquid volume. The dependence of the liquid morphology and rupture distance on the diameter and areal fraction of hydrophilic islands, liquid volumes, as well as loading pressure is also characterized both theoretically and experimentally. The thermal resistance in the on-state is experimentally characterized for ionic liquids, which are promising for practical applications due to their negligible vapor pressure. A life testing setup is constructed to evaluate the reliability of the interface under continued switching conditions at relatively high switching frequencies.
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