Ceramic Substrate Warpage Control via Brazing Thickness
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Solution Overview
Problem
Ceramic substrates used in high-heat applications experience warpage due to thickness differences in brazing material layers, increasing manufacturing costs and complexity.
Innovation Solution
A ceramic substrate design with a flat plate-shaped insulating base, where the difference in thickness between the first and second brazing material layers is 4.0 µm or less, and a manufacturing method involving screen printing to ensure uniform application of brazing material, matching the number of screen printing cycles for both layers to minimize warpage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the brazing material is applied using screen printing method, then the brazing material can be applied to both surfaces of the ceramic base, but the difference in thickness between the first brazing material layer and the second brazing material layer causes warpage of the ceramic substrate
Solution Approach 1:
The patent applies parameter changes by controlling the number of screen printing cycles for each surface. Specifically, the first surface is printed an odd number of times (1, 3, or 5 times) and the second surface is printed an even number of times (2, 4, or 6 times), ensuring the thickness difference between brazing material layers is 4.0 μm or less. This parameter control resolves the warpage issue while maintaining ease of manufacture through screen printing.
2Manufacturing precision
If the brazing material thickness difference is reduced to suppress warpage, then the substrate warpage is suppressed, but the manufacturing process becomes more complex
Solution Approach 1:
The patent employs periodic action through repeated screen printing cycles. By printing the first surface an odd number of times and the second surface an even number of times, the process creates a systematic, periodic pattern that ensures uniform thickness control. This approach suppresses warpage while keeping the process control manageable through clear, repeatable printing cycles.
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 solution effectively suppresses warpage while reducing manufacturing costs by maintaining a uniform thickness difference between brazing material layers, ensuring minimal deviation in substrate warpage at room temperature.
Implementation Method 1
a first brazing material layer provided on a first main surface of the insulating base; a second brazing material layer provided on a second main surface of the insulating base
Implementation Method 2
a first metal layer comprising a metal and being fixed through the first brazing material layer to the insulating base on the first main surface side; and a second metal layer comprising a metal and being fixed through the second brazing material layer to the insulating base on the second main surface side
Data Source
AI summary
A ceramic substrate is provided with a flat plate-shaped insulating base including a ceramic, a first brazing material layer provided on a first main surface of the insulating base, a second brazing material layer provided on a second main surface of the insulating base, a first metal layer including a metal and being fixed through the first brazing material layer to the insulating base on a first main surface-side, and a second metal layer including a metal and being fixed through the second brazing material layer to the insulating base on a second main surface-side. A difference between a thickness of the first brazing material layer and a thickness of the second brazing material layer at a given point is 4.0 µm or less.