Nitride Composite Sheet Surface Control for Uniform Heat Dissipation
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Solution Overview
Problem
Conventional composite sheets used in laminates for heat dissipation, such as in LED lighting and in-vehicle power modules, exhibit variations in heat dissipation properties due to irregular surface roughness, leading to inconsistent thermal conductivity when adhered to metal substrates.
Innovation Solution
A composite sheet with a nitride sintered body and a semi-cured thermosetting resin composition, where the line roughness Rz on at least one principal surface is 10 μm or less, and the arithmetic average roughness Ra is 2.0 μm or less, is used, reducing variations in resin layer thickness and enhancing adhesiveness and insulating properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional composite sheet with irregular surface is used, then the manufacturing process is simple, but the heat dissipation properties vary and thermal conductivity is inconsistent
Solution Approach 1:
The patent controls the surface roughness parameters (Ra ≤ 2.0 μm and Rz ≤ 10 μm) of the composite sheet through manufacturing process optimization. By establishing specific parameter ranges for surface roughness, the invention ensures consistent thermal conductivity and heat dissipation properties when the composite sheet is laminated with metal substrates, resolving the contradiction between manufacturing simplicity and heat dissipation consistency.
2Manufacturing precision
If the surface roughness is reduced to improve heat dissipation consistency, then thermal conductivity uniformity improves, but manufacturing complexity increases
Solution Approach 1:
The patent specifies preliminary surface roughness control (Ra ≤ 2.0 μm and Rz ≤ 10 μm) before lamination to ensure consistent thermal conductivity. By establishing surface quality requirements in advance and controlling them through the manufacturing process, the invention achieves uniform heat dissipation without requiring complex post-processing or additional manufacturing steps, thus balancing precision requirements with manufacturing feasibility.
3Manufacturing precision
If a smooth surface is achieved through precise manufacturing, then resin layer thickness variation is reduced, but production time and cost increase
Solution Approach 1:
The patent establishes specific surface roughness parameter ranges (Ra ≤ 2.0 μm and Rz ≤ 10 μm) that directly control resin layer thickness consistency during lamination. By optimizing the manufacturing process to meet these parameter specifications, the invention reduces resin layer variation and improves thermal conductivity uniformity while maintaining production efficiency, avoiding the need for excessively complex or time-consuming manufacturing processes.
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 composite sheet provides consistent and improved heat dissipation properties when laminated with metal substrates, reducing thermal resistance and ensuring uniform heat dissipation across the interface.
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
used is a composite (heat dissipation member) composed of a resin and ceramics such as boron nitride
Data Source
AI summary
One aspect of the present invention provides a composite sheet which comprises a nitride sintered body having a porous structure and a semi-cured product of a thermosetting resin composition impregnated into the nitride sintered body, the line roughness Rz specified by JIS B 0601:2013 of at least one main surface being 10 μm or less.