Curved Metal-SiC Heat Dissipation Member for Easier Module Alignment
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Solution Overview
Problem
The challenge in manufacturing power modules is the difficulty in aligning and connecting components to a curved heat dissipation member, which affects manufacturing stability and yield.
Innovation Solution
A plate-shaped heat dissipation member with a metal-silicon carbide composite containing aluminum or magnesium, where at least one main surface is curved convexly, and the flatness of this surface is designed to be significantly different from the opposite surface by 10 μm or more, as defined by JIS B 0621.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heat dissipation member surface is made convex to improve joinability with heat dissipation fins, then heat transference is improved, but alignment and connection of components to the opposite surface becomes difficult
Solution Approach 1:
The invention applies different surface curvatures to different surfaces of the heat dissipation member. The first surface (joining surface) has a larger curvature radius to provide convexity for improved joinability with heat dissipation fins, while the second surface (component connection surface) has a smaller curvature radius to maintain relative flatness for easier component alignment and connection. This local differentiation of surface properties resolves the contradiction between improved joinability and manufacturing ease.
2Reliability
If the heat dissipation member surface is made convex to prevent gap formation, then heat transference is improved, but manufacturing stability and yield decrease
Solution Approach 1:
The invention differentiates the curvature characteristics between the first surface and second surface. The first surface is designed with convex curvature (larger radius) to eliminate gaps and improve heat transference, while the second surface maintains relative flatness (smaller radius) to facilitate stable mass production and component connection, thereby improving manufacturing stability and yield.
Solution Approach 2:
The invention creates an asymmetric curvature configuration where the first surface has a different curvature radius than the second surface. This asymmetry allows the heat dissipation member to optimize for both heat transference (convex first surface) and manufacturing stability (flatter second surface), resolving the contradiction between these two requirements.
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 design improves manufacturing stability and yield by enhancing joinability with heat dissipation fins while facilitating easier alignment and connection of components to the heat dissipation member.
Implementation Method 1
a heat dissipation member formed of a metal-silicon carbide composite has been used instead of copper in the related art
Data Source
AI summary
A plate-shaped heat dissipation member includes a metal-silicon carbide composite containing aluminum or magnesium, in which at least one of two main surfaces of the heat dissipation member is curved to be convex in an outward direction of the heat dissipation member, and when a flatness of the one main surface defined by JIS B 0621 is represented by f1 and a flatness of the other main surface different from the one main surface defined by JIS B 0621 is represented by f2, f2 is less than f1 by 10 μm or more.