Aluminum-Diamond Composite Lamination for Low-Resistance Interfaces
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Solution Overview
Problem
The production of aluminum-diamond composites is hindered by the need for costly and complex processing methods like laser processing, which can lead to surface defects and reduced adhesion of metal plating, thereby increasing thermal resistance.
Innovation Solution
A method involving a laminate structure with a diamond powder composition layer in a porous material, where a melt of aluminum is press-fitted to impregnate the composition layer and form metal layers on the laminate structure, eliminating the need for laser processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser processing is used to process the aluminum-diamond composite, then the composite can be processed into product shapes, but the cut surface exposes diamond powder which deteriorates adhesion of metal plating and joining properties to brazing filler metal
Solution Approach 1:
The invention applies preliminary action by forming a metal-containing layer on the surface of the aluminum-diamond composite before any subsequent processing or assembly steps. This pre-formed layer prevents diamond powder exposure and adhesion deterioration from the outset, eliminating the need for post-processing repairs or additional coating steps.
Solution Approach 2:
The metal-containing layer acts as an intermediary between the diamond-containing composite and external elements (metal plating, brazing filler metal). This intermediate layer prevents direct contact between diamond powder and plating materials, thereby maintaining adhesion properties while still allowing thermal and mechanical functionality.
2Ease of manufacture
If laser processing is used to process the aluminum-diamond composite, then the composite can be processed into product shapes, but thermal resistance increases in the contact interface with another member
Solution Approach 1:
The metal-containing layer is formed in advance on the composite surface, creating a thermally conductive interface before assembly. This preliminary metallization ensures low thermal resistance at the contact interface, preventing heat accumulation and maintaining efficient thermal transfer throughout the device lifecycle.
Solution Approach 2:
The metal-containing layer serves as a thermal intermediary, providing a low-resistance thermal path between the diamond composite and contacting members. This intermediate metallic layer compensates for any surface irregularities and ensures optimal thermal contact without requiring direct diamond-to-diamond or diamond-to-metal contact.
3Reliability
If conventional production methods are used, then aluminum-diamond composites can be produced, but the production time is long and processing cost is high due to multiple steps including laser processing
Solution Approach 1:
The invention merges the composite formation process with the surface metallization process into a single integrated step. By forming the metal-containing layer simultaneously with the composite structure during manufacturing, the method eliminates separate laser processing and coating steps, thereby reducing production time and cost while maintaining product quality.
Solution Approach 2:
The metal-containing layer is formed preliminarily during the composite manufacturing process itself, rather than as a subsequent separate operation. This preliminary integration of surface treatment into the base manufacturing process eliminates multiple processing steps and reduces overall production time while ensuring consistent quality.
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
This method allows for the simpler and faster production of aluminum-diamond composites with improved thermal shock resistance and reduced thermal resistance in the contact interface, while avoiding the costs and complexities associated with traditional processing methods.
Implementation Method 1
press-fitting a melt of a metal containing aluminum into a space between the porous material and the laminate structure and impregnating the composition layer with the melt
Implementation Method 2
press-fitting a melt of a metal containing aluminum into a space between the porous material and the laminate structure
Data Source
AI summary
A production method for an aluminum-diamond composite having a step of providing a laminate structure including a composition layer containing a diamond powder in an opening of a flat plate-like porous material having the opening so as to be separated from an inner circumferential surface of the opening and a step of press-fitting a melt of a metal containing aluminum into a space between the porous material and the laminate structure and impregnating the composition layer with the melt to form a composited part containing aluminum and diamond and forming metal layers on at least side surfaces of the laminate structure, in which the laminate structure includes a first mold release plate, a first inorganic layer, the composition layer, a second inorganic layer and a second mold release plate in this order.