Patterned Sputtered Coating for Automotive Heat Dissipation Surfaces
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Solution Overview
Problem
Conventional automobile electronic modules face overheating issues due to inadequate corrosion resistance and bonding strength of metal heat dissipation devices, leading to performance deterioration and damage.
Innovation Solution
A method involving the formation of a patterned sputtered metal layer on a metal heat dissipation device with a selectively removable masking area, where the metal layer is 1-3 μm thick and covers less than 90% of the surface, enhancing soldering and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal heat dissipation device is used for automobile electronic modules, then heat dissipation function is provided, but corrosion resistance and bonding strength are insufficient
Solution Approach 1:
The patent applies composite materials by combining a metal heat dissipation device base with a patterned coating layer consisting of multiple functional layers (primer layer, intermediate layer, and topcoat layer). This composite structure provides both the heat dissipation function of the metal base and the enhanced corrosion resistance and bonding strength of the multi-layer coating system, resolving the contradiction between functional performance and material limitations.
Solution Approach 2:
The patent implements local quality through the patterned coating structure where different regions of the surface have different coating configurations. The patterned coating includes exposed metal regions and coated regions, creating local variations in properties such as corrosion resistance, bonding strength, and heat dissipation characteristics. This allows optimization of specific areas for different functions while maintaining overall device performance.
2Reliability
If the sputtered metal layer covers the entire upper surface, then corrosion resistance is maximized, but soldering functionality is reduced
Solution Approach 1:
The patent applies local quality by creating a patterned coating where specific regions have different properties. The pattern includes exposed metal regions that provide excellent soldering functionality and coated regions that provide corrosion resistance. This spatial differentiation allows both contradictory requirements (corrosion resistance and soldering functionality) to be satisfied in different locations on the same surface.
Solution Approach 2:
The patent segments the surface into distinct functional zones through the patterned coating structure. The coating is divided into covered areas and exposed areas, creating separate functional regions. The exposed metal regions are specifically designed for soldering operations, while the coated regions provide corrosion protection, thus segmenting the surface to fulfill multiple contradictory functions simultaneously.
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 method effectively improves the soldering and corrosion resistance of the heat dissipation device, ensuring better performance and durability.
Implementation Method 1
forming a sputtered metal layer that is patterned on an upper surface of the metal heat dissipation device by sputtering
Data Source
AI summary
A method for manufacturing a patterned surface coating of an automobile heat dissipation device and an automobile heat dissipation device having a patterned surface coating. The method for manufacturing the patterned surface coating of the automobile heat dissipation device includes providing a metal heat dissipation device, and forming a sputtered metal layer that is patterned on an upper surface of the metal heat dissipation device by sputtering, allowing a thickness of the sputtered metal layer to be between 1 μm and 3 μm, and allowing the sputtered metal layer to cover an area less than 90% of an area of the upper surface of the metal heat dissipation device.