Ceramic Substrate Brazing via Filler Layer for Adhesion
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Solution Overview
Problem
Conventional DBC ceramic substrate manufacturing methods require high-temperature sintering, expensive equipment, and complex processes, leading to low productivity and adhesion issues between the metal foil and ceramic base, particularly under thermal shock conditions.
Innovation Solution
A ceramic substrate manufacturing method involving brazing, where a ceramic base and metal foil are unified through a brazing filler layer formed by printing or plating, with seed layers ensuring strong bonding and precise control over the brazing joint layer thickness, eliminating the need for high-temperature sintering and improving adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-temperature sintering is used to bond metal foil to ceramic base, then bonding is achieved, but manufacturing cost increases due to expensive sintering equipment
Solution Approach 1:
The patent changes the bonding temperature parameter from high-temperature sintering (1000-1100°C) to low-temperature brazing (600-800°C), thereby achieving bonding strength without requiring expensive high-temperature sintering equipment. The brazing process uses a filler metal that melts at lower temperature to create the bond.
Solution Approach 2:
The patent introduces a brazing filler metal as an intermediary substance between the metal foil and ceramic base. This filler metal facilitates bonding at lower temperatures by melting and forming intermetallic compounds, eliminating the need for direct high-temperature sintering of the metal-ceramic interface.
2Strength
If high-temperature sintering is used to form interfacial bonding, then bonding is achieved, but manufacturing time increases and productivity decreases
Solution Approach 1:
The patent changes the bonding temperature parameter from 1000-1100°C sintering to 600-800°C brazing, which significantly reduces the heating time required. The lower temperature process allows faster heating rates and shorter holding times, thereby increasing manufacturing speed and productivity.
3Strength
If conventional sintering process is used, then bonding is achieved, but adhesion strength is insufficient under thermal shock conditions
Solution Approach 1:
The brazing filler metal acts as an intermediary that creates a more reliable bond under thermal shock. The filler metal forms intermetallic compounds and eutectic structures that accommodate thermal expansion differences between metal and ceramic, preventing delamination during thermal cycling.
Solution Approach 2:
The patent creates a composite bonding structure consisting of the base metal, brazing filler metal, and ceramic substrate. This composite structure leverages the complementary properties of each material to achieve both strength and thermal shock resistance, with the brazing layer acting as a transition zone.
4Strength
If complex oxidation and sintering processes are used, then bonding is achieved, but manufacturing process becomes complicated
Solution Approach 1:
The patent extracts and eliminates the complex oxidation step from the manufacturing process. The brazing process directly bonds the metal foil to the ceramic base through the filler metal without requiring preliminary oxidation of the metal surface or formation of intermediate oxide layers, thereby simplifying the overall process.
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 enhances adhesion strength, reduces manufacturing costs, simplifies the process, and improves heat dissipation by minimizing the thickness of the brazing joint layer, while maintaining reliability and productivity.
Implementation Method 1
laminating the metal foil on the brazing filler layer and brazing
Implementation Method 2
heating the brazing filler layer to heat the brazing filler layer, which is melted and pressurized
Implementation Method 3
heating the brazing filler layer to heat the brazing filler layer, which is melted and pressurized between a lower pressing jig portion and an upper pressing jig portion
Data Source
AI summary
A ceramic substrate manufacturing method and a ceramic substrate manufactured thereby, may include a seed layer, a brazing filler layer, and a metal foil that are laminated on a ceramic substrate and that are brazed such that the metal foil is firmly bonded to the ceramic substrate by a brazing joint layer. Such methods and devices may substantially improve the adhesion of the metal foil and the ceramic substrate.