Graphite Structure With Multi-Layer Metal Coating For Thermal Management
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Solution Overview
Problem
Existing graphite structures used for thermal management in semiconductor and electronic devices face challenges in achieving high thermal conductivity in both the plane and thickness directions due to strong anisotropy and limitations in metal coating configurations.
Innovation Solution
A graphite structure is developed with a graphite plate having through-holes, a coating layer of a first metal capable of forming compounds with carbon, a porous second metal covering the coating layer, and a third metal covering the porous second metal, enhancing thermal conductivity in both directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple metal coating is applied to graphite, then ease of manufacture is improved, but bonding strength and thermal conductivity in the thickness direction deteriorate
Solution Approach 1:
The invention divides the metal coating into three distinct layers, each with specific functions: the first metal coating layer (5-50 nm thick) bonds to graphite and forms compounds with carbon; the second metal coating layer (50-200 nm thick) with 5-30% porosity provides thermal conduction pathways; and the third metal coating layer provides additional thermal conductivity enhancement. This segmentation allows each layer to optimize its function while maintaining overall manufacturability.
Solution Approach 2:
The invention applies different metal materials and structures to different locations and depths of the coating system. The first metal layer contacts the graphite surface directly with compound-forming capability, the second layer provides porous thermal pathways, and the third layer provides bulk thermal conduction. This local differentiation of material properties optimizes thermal conductivity in the thickness direction while keeping the process manufacturable.
2Temperature
If the graphite plate is coated with metal to improve thermal conductivity, then thermal conduction is improved, but the complexity of the structure increases
Solution Approach 1:
The metal coating layers serve multiple functions simultaneously: they provide thermal conduction pathways in the thickness direction, enhance bonding strength between graphite and surrounding components, prevent oxidation of the graphite, and the porous second layer provides stress relief during thermal cycling. This multi-functionality justifies the increased structural complexity by delivering multiple performance benefits from a single coating system.
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 configuration significantly increases thermal conductivity in both the plane and thickness directions, enabling effective heat dissipation and maintaining device functionality, especially in applications with local heat sources.
Implementation Method 1
a coating layer covering an inner peripheral surface of the at least one through-hole and an entire circumference of the graphite plate, the coating layer including a first metal capable of forming a compound with carbon atoms constituting the graphite plate
Implementation Method 2
a porous second metal covering an entire circumference of the coating layer including a region surrounded by the inner peripheral surface of the at least one through-hole
Data Source
AI summary
Provided are a graphite plate including at least one or more through-holes passing through the graphite plate in a direction orthogonal to a basal surface of the graphite plate, a coating layer covering an inner peripheral surface of the at least one through-hole and an entire circumference of the graphite plate, the coating layer including a first metal capable of forming a compound with carbon atoms constituting the graphite plate, a porous second metal covering an entire circumference of the coating layer including a region surrounded by the inner peripheral surface of the at least one through-hole, and a third metal covering an entire circumference of the porous second metal, the graphite plate and the porous second metal being bonded to each other with the coating layer interposed the graphite plate and the porous second metal, and the third metal being bonded to the porous second metal.