Aluminum Composite Thermal Shield via Sintering
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Solution Overview
Problem
Existing materials for thermal shields, such as aluminum casting products, have high thermal conductivity, leading to heat-related issues like deterioration of surrounding components and shortened product lifespan in electronic and automotive applications.
Innovation Solution
A method for manufacturing a composite material for thermal shields by compounding aluminum or aluminum alloy powders with polymer or ceramic powders through pressureless sintering or spark plasma sintering, resulting in a heterogeneous material with low thermal conductivity suitable for thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum casting products are used for thermal shields, then mechanical strength and structural integrity are improved, but thermal conductivity increases leading to heat-related issues
Solution Approach 1:
The patent applies composite materials by combining aluminum powder with ceramic or polymer powders to create a metal matrix composite. This composite structure maintains the mechanical strength benefits of aluminum while the ceramic or polymer phases provide thermal insulation, resolving the contradiction between strength and thermal conductivity.
Solution Approach 2:
The patent implements local quality by creating regions with different thermal conductivities within the material structure. The ceramic or polymer phases are distributed throughout the aluminum matrix to create localized thermal barrier regions, allowing different parts of the material to have different thermal properties while maintaining overall structural integrity.
2Object-affected harmful factors
If polymer or ceramic powders are added to reduce thermal conductivity, then thermal insulation properties are improved, but material homogeneity deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the material into distinct phases (aluminum matrix and dispersed ceramic or polymer particles). This segmentation allows each phase to maintain its own properties while contributing to the overall composite performance, with the aluminum providing strength and the ceramic/polymer providing thermal insulation.
Solution Approach 2:
The patent controls the volume fraction of ceramic or polymer powders within specific ranges (15-70% by volume) to optimize the balance between thermal insulation and material homogeneity. By adjusting these parameters, the composite achieves desired thermal properties while maintaining sufficient structural uniformity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces a composite material with thermal conductivity of 10 W/mk or less, effectively addressing heat-related issues in electronic and automotive components by providing enhanced thermal insulation and mechanical properties.
Implementation Method 1
preparing a composite material by sintering the mixed powder through pressureless sintering or spark plasma sintering
Implementation Method 2
preparing a composite material by sintering the mixed powder through pressureless sintering or spark plasma sintering
Data Source
AI summary
A method of manufacturing a composite material for thermal shields, and a composite material manufactured by the method are proposed. The method may include preparing a mixed powder including (i) a metal powder including a powder of aluminum or aluminum alloy and (ii) a polymer or ceramic powder. The method may also include sintering the mixed powder through pressureless sintering or spark plasma sintering to produce a composite material. According to the present disclosure, a powder of polymer, ceramic, and/or metal which have a relatively low level of thermal conductivity can be compounded with a metal material including aluminum through a sintering process of powder metallurgy, such as pressureless sintering or spark plasma sintering. Thus, a heterogeneous composite material with a low-level thermal conductivity (10 W/mk or less) can be obtained, and the composite material can be used as a material for various thermal shields.