Curved Heat Dissipation Member for Stable Power Module Bonding
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Solution Overview
Problem
The challenge in manufacturing power modules is the difficulty in aligning and connecting components to curved heat dissipation members, which affects manufacturing stability and yield, especially when the heat dissipation member's surface is convex, leading to potential gaps and reduced thermal conductivity.
Innovation Solution
A plate-shaped heat dissipation member with one surface convex outward and the other surface convex inward, featuring a specific curvature design where the ratio of local curve to overall curve is 1.1 or more, allowing for improved alignment and connection stability during power module assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heat dissipation member surface is made convex to prevent gaps and improve joinability, then thermal conductivity and joinability are improved, but alignment and connection of components become difficult
Solution Approach 1:
The invention applies different curvature characteristics to different regions of the heat dissipation member surface. The center portion has a larger radius of curvature (flatter) to facilitate alignment and connection of components, while the peripheral portion has a smaller radius of curvature (more convex) to prevent gaps and improve joinability. This local differentiation resolves the contradiction between improved joinability and ease of manufacturing.
2Reliability
If the heat dissipation member surface is made convex to improve joinability, then adhesion to other components is improved, but manufacturing stability and yield decrease
Solution Approach 1:
By making the center portion flatter (larger radius of curvature) and the peripheral portion more convex (smaller radius of curvature), the invention locally optimizes different regions for different functions. The flat center region ensures manufacturing stability and ease of component connection, while the convex peripheral region ensures strong adhesion and prevents gaps, thereby resolving the contradiction between adhesion and manufacturing stability.
3Reliability
If the heat dissipation member surface is made convex to prevent gap formation, then thermal conductivity is improved, but component connection stability deteriorates
Solution Approach 1:
The invention differentiates the radius of curvature between center and peripheral portions to locally optimize functions. The flatter center portion (larger radius) provides stable alignment and connection for components, while the convex peripheral portion (smaller radius) prevents gap formation to maintain thermal conductivity, thus resolving the contradiction between thermal conductivity and connection stability.
4Reliability
If a uniform convex surface is used to improve joinability, then gap prevention is improved, but alignment of components becomes difficult
Solution Approach 1:
The invention applies a larger radius of curvature to the center portion and a smaller radius of curvature to the peripheral portion. This local differentiation allows the center to remain flat for easy alignment of components, while the periphery becomes convex to prevent gaps, resolving the contradiction between gap prevention and alignment ease.
5Ease of manufacture
If the peripheral portion has the same curvature as the center portion, then manufacturing is simplified, but joinability and gap prevention deteriorate
Solution Approach 1:
The invention specifies that the peripheral portion should have a smaller radius of curvature than the center portion, creating local differentiation. This allows the peripheral region to be more convex for improved joinability and gap prevention, while the center remains flatter for component connection, resolving the contradiction between manufacturing simplicity and joinability.
6Ease of operation
If the center portion is made flatter to improve alignment, then component connection is facilitated, but gap prevention and joinability worsen
Solution Approach 1:
The invention creates a gradient in radius of curvature where the center portion has a larger radius (flatter) and the peripheral portion has a smaller radius (more convex). This local differentiation allows the center to be optimized for alignment and component connection, while the periphery is optimized for gap prevention and joinability, resolving the contradiction between alignment ease and joinability.
Data Source
AI summary
Among two main surfaces of a heat dissipation member, one main surface is curved to be convex in an outward direction and the other convex in an inward direction. When a straight line passing through both endpoints P1 and P2 of the curve is l1, a point at which a distance to l1 on the curve is maximum is Pmax, an intersection point between l1 and a perpendicular drawn from Pmax to l1 is P3, a middle point of a line segment P1P3 is P4, an intersection point between the curve and a straight line that passes through P4 and is perpendicular to l1 is Pmid, a length of the line segment P1P3 is L, a length of a line segment P3Pmax is H, and a length of a line segment P4Pmax is h, (2 h/L)/(H/L) is 1.1 or more.