Nitride Composite Sheet Surface Control for Uniform Heat Dissipation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional composite sheets used in laminates for electronic components like LED lighting and in-vehicle power modules exhibit variations in heat dissipation properties, leading to inconsistent thermal conductivity when bonded with metal substrates.
Innovation Solution
A composite sheet with a nitride sintered body having a porous structure and a semi-cured thermosetting resin composition, where the principal surface has a line roughness Rz of 10 µm or less, is used, along with a method involving wire saw cutting to produce the sheet, ensuring uniform resin layer thickness and improved adhesiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional composite sheet with larger surface irregularities is used, then the manufacturing process is simpler, but the resin layer thickness varies at the interface with the metal substrate, causing variations in thermal conductivity
Solution Approach 1:
The patent applies parameter changes by controlling the line roughness Rz to 10 μm or less through specific wire saw cutting conditions (wire reciprocating linear speed of 155 to 1000 mm/min and table moving speed of 4 mm/min). This parameter control resolves the contradiction by achieving smooth surfaces that ensure uniform resin layer thickness and consistent thermal conductivity, while the wire saw cutting method remains a standard manufacturing process.
2Manufacturing precision
If a composite sheet with smoother surface is used, then the resin layer thickness becomes more uniform improving heat dissipation, but the manufacturing process becomes more complex
Solution Approach 1:
The patent resolves this contradiction by optimizing cutting parameters (wire reciprocating linear speed of 155 to 1000 mm/min and table moving speed of 4 mm/min) to achieve line roughness Rz of 10 μm or less. This creates uniform resin layer thickness at the interface, ensuring consistent heat dissipation properties without requiring complex additional manufacturing steps.
3Manufacturing precision
If conventional composite sheets are used, then the manufacturing process is straightforward, but variations in thermal conductivity occur at different positions of the laminate
Solution Approach 1:
The patent addresses this contradiction by controlling the line roughness Rz to 10 μm or less through optimized wire saw cutting parameters. This ensures uniform resin layer thickness across the entire laminate surface, eliminating positional variations in thermal conductivity while maintaining production efficiency through a streamlined cutting process.
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 solution results in a laminate with enhanced heat dissipation properties and reduced variations in thermal conductivity across the interface, providing consistent and improved heat management.
Implementation Method 1
The composite sheet comprises the semi-cured product of the thermosetting composition and thus may adhere to an adherend
Implementation Method 2
there is a problem of efficient dissipation of heat generated during use... a composite (heat dissipation member) composed of a resin and ceramics such as boron nitride
Data Source
Figure 1
Figure 2
Figure 3
AI summary
One aspect of the present disclosure provides a composite sheet including: a nitride sintered body having a porous structure; and a semi-cured product of a thermosetting resin composition impregnated into the nitride sintered body, at least one principal surface of the composite sheet having line roughness Rz, specified in JIS B0601: 2013, of 10 µm or less.