Curved Al-SiC Heat Dissipation Member for Gap-Free Module Joining
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Solution Overview
Problem
The challenge in manufacturing power modules lies in the difficulty of 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 or concave, 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 that allows for improved alignment and connection, manufactured using a metal-silicon carbide composite with aluminum or magnesium, and a method involving heating and pressing between convex and concave molds to achieve the desired curvature.
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 adhesion are improved, but alignment and connection of components become difficult
Solution Approach 1:
The invention divides the heat dissipation member surface into multiple regions with different curvatures: a first region with convex curvature for improved joinability, and a second region with different curvature characteristics for improved alignment. This segmentation allows each region to fulfill its specific function independently.
Solution Approach 2:
Different portions of the heat dissipation member surface are given different local properties: the first region has convex curvature optimized for preventing gaps and improving thermal contact, while the second region has different curvature optimized for component alignment. This local differentiation resolves the contradiction between joinability and alignment.
2Reliability
If the heat dissipation member surface is made convex to improve adhesion, then gap formation is prevented, but manufacturing stability and yield decrease
Solution Approach 1:
The surface is segmented into functional zones: the first region provides adhesion through convex curvature, while the second region facilitates manufacturing through different curvature characteristics, thereby improving overall manufacturing stability and yield.
Solution Approach 2:
By giving different local curvature properties to different regions, the invention enables the adhesion-critical area to maintain convex shape while other areas have optimized curvature for manufacturing stability, resolving the contradiction between adhesion and productivity.
3Device complexity
If a single curved surface is used for both heat dissipation fin connection and power element connection, then manufacturing is simplified, but alignment and connection difficulty increase
Solution Approach 1:
The single surface is segmented into distinct functional regions: the first region for heat dissipation fin connection with convex curvature, and the second region for power element connection with different curvature. This maintains relative structural simplicity while enabling differentiated functionality for each connection type.
Solution Approach 2:
Different local curvature characteristics are applied to different connection areas on the same surface, allowing each connection type to be optimized for its specific requirements without requiring entirely separate surfaces or components.
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 enhances manufacturing stability and yield by facilitating easier alignment and connection of components, reducing gaps, and improving thermal conductivity and joinability.
Implementation Method 1
a heat dissipation member (1) including a metal-silicon carbide composite containing aluminum or magnesium
Implementation Method 2
a method of manufacturing the heat dissipation member (1), the method including: a preparation step of preparing a metal-silicon carbide composite containing aluminum or magnesium; and a heating press step of interposing the metal-silicon carbide composite between convex and concave molds and heating and pressing the metal-silicon carbide composite
Data Source
Figure 1(a)~1(b)
Figure 2~3
Figure 4
AI summary
Provided is a substantially rectangular and plate-shaped heat dissipation member including a metal-silicon carbide composite containing Al or Mg. Among two main surfaces of the heat dissipation member, one main surface is curved to be convex in an outward direction of the heat dissipation member and the other main surface is curved to be convex in an inward direction of the heat dissipation member. In a curve C of the other main surface in a cross-sectional view of the heat dissipation member showing a cross-section that is substantially perpendicular to the heat dissipation member and passes both middle points of two short sides of the other main surface, when a straight line passing through both endpoints P1 and P2 of the curve C is represented by l1, a point at which a distance to l1 on the curve C is maximum is represented by Pmax, an intersection point between l1 and a perpendicular drawn from Pmax to l1 is represented by P3, a middle point of a line segment P1P3 is represented by P4, an intersection point between the curve C and a straight line that passes through P4 and is perpendicular to l1 is represented by Pmid, a length of the line segment P1P3 is represented by L, a length of a line segment P3Pmax is represented by H, and a length of a line segment P4Pmid is represented by h, (2h/L)/(H/L) is 1.1 or more.