Heat Sink Coating Process for Laser Thermal Management

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

High-power laser systems face limited reliability and lifetime due to erosion and corrosion issues in their heat sinks, particularly in copper microchannel coolers, which affect the performance and longevity of laser emitters.

Innovation Solution

Thin-film deposition, specifically using atomic layer deposition (ALD) to apply protective films like TiO2, SiO2, and Al2O3 on the internal surfaces of heat sinks, enhancing their corrosion and erosion resistance while maintaining thermal conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If copper microchannel coolers are used for heat dissipation, then thermal conductivity is improved, but corrosion and erosion resistance deteriorates

Engineering Contradiction:

Improvethermal conductivityVSAvoidcorrosion and erosion resistance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent applies composite materials by depositing protective films (such as aluminum oxide, titanium oxide, or diamond-like carbon) onto the copper microchannel cooler surface. This creates a composite structure where the copper base provides high thermal conductivity while the protective film layer provides corrosion and erosion resistance, effectively resolving the contradiction between thermal performance and durability.

Inventive Principle:

Principle #40Composite materials

2Reliability

If protective films are deposited on heat sink surfaces, then corrosion and erosion resistance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecorrosion and erosion resistanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical coating methods with physical vapor deposition (PVD) or chemical vapor deposition (CVD) processes. These deposition techniques allow for precise, controlled application of protective films at the molecular level, reducing manufacturing variability and simplifying quality control despite the added process step.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent controls deposition parameters such as film thickness (typically 1-10 micrometers), deposition temperature, and precursor composition to optimize both protective performance and manufacturing efficiency. By carefully adjusting these parameters, the process achieves reliable corrosion protection while maintaining manufacturing feasibility.

Inventive Principle:

Principle #35Parameter changes

3Duration of action of stationary object

If thin protective films are deposited on internal surfaces of heat sinks, then lifetime is extended, but manufacturing throughput decreases

Engineering Contradiction:

Improveheat sink lifetimeVSAvoidmanufacturing throughput

Core Design Contradiction:

Duration of action of stationary objectVSProductivity

Solution Approach 1:

The patent applies protective films to the internal surfaces of heat sinks before final assembly, allowing the deposition process to occur on accessible surfaces. This preliminary action approach enables efficient coating application without requiring disassembly of complex internal channels during the deposition process, thereby maintaining reasonable manufacturing throughput.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses extremely thin protective films (1-10 micrometers) that can be deposited rapidly using modern PVD/CVD equipment. These thin films provide sufficient corrosion and erosion protection while minimizing deposition time, thus extending heat sink lifetime without significantly reducing manufacturing throughput.

Inventive Principle:

Principle #30Flexible shells and thin films

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 protective films significantly extend the lifespan and reliability of heat sinks by preventing corrosion and erosion, ensuring continuous operation of high-power laser systems without compromising thermal management.

Implementation Method 1

enhancing the corrosion and erosion resistance

Methodology Applied

Scientific EffectCorrosion resistance:

Implementation Method 2

enhancing the corrosion and erosion resistance

Methodology Applied

Scientific EffectErosion resistance:

Implementation Method 3

transfers the heat generated by the beam emitter to a fluid medium such as air or a cooling liquid

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10630049B2Coating process for laser heat sinks

Publication Date: 2020.04.21 WBC PHOTONICS INC

AI summary

In various embodiments, passivation layers are deposited on internal surfaces of cooling channels defined within heat sinks for electronic devices such as laser beam emitters, the passivation layers retarding or substantially preventing erosion and/or corrosion of the heat sinks.