PEO Ceramic Coated Power Substrate for High Voltage Thermal Management
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Solution Overview
Problem
Anodised aluminium substrates fail to meet the requirements for high power electronic devices due to insufficient voltage withstand and thermal dissipation capabilities, limiting their application in electronic equipment.
Innovation Solution
A ceramic coating generated by plasma electrolytic oxidation (PEO) is applied to a metal base, providing a voltage withstand of over 3.5 kV and enhanced thermal conductivity, allowing for the use of metals like magnesium and enabling the creation of a heat sink, which increases design freedom and efficiency in heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If anodised aluminium substrate is used, then electrical insulation and thermal conduction are improved, but voltage withstand capability deteriorates
Solution Approach 1:
The invention uses a composite structure consisting of a metal base (aluminium or magnesium alloy) combined with a ceramic coating layer formed through plasma electrolytic oxidation. This composite material provides both the electrical insulation and high voltage withstand capability of the ceramic layer and the thermal conduction properties of the metal base, resolving the contradiction between voltage withstand and thermal dissipation.
Solution Approach 2:
The invention changes the physical and chemical parameters of the substrate surface by applying a ceramic coating through plasma electrolytic oxidation. This process transforms the metal surface into a ceramic layer with different electrical and thermal properties, enabling the substrate to achieve both high voltage withstand capability and thermal dissipation performance.
2Reliability
If anodised aluminium substrate is used, then thermal conduction is improved, but voltage breakdown resistance deteriorates
Solution Approach 1:
The composite structure of metal base with ceramic coating provides both high voltage breakdown resistance from the ceramic layer and effective heat dissipation from the metal base, allowing the substrate to handle high power devices safely.
Solution Approach 2:
By changing the surface parameters through plasma electrolytic oxidation to create a ceramic coating, the substrate achieves both high voltage breakdown resistance and maintained thermal conduction capability.
3Reliability
If anodised aluminium substrate is used, then electrical insulation is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The ceramic coating provides excellent electrical insulation while the metal base maintains high thermal conduction, creating a composite material that simultaneously achieves both electrical insulation and heat dissipation capabilities required for high power electronic devices.
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 PEO-coated substrate effectively supports high power devices by increasing voltage withstand and thermal efficiency, reducing the need for thick epoxy layers and minimizing thermal resistance, while allowing the use of non-anodizable metals like magnesium, thus enabling broader applications in electronic equipment.
Implementation Method 1
A ceramic coating generated by plasma electrolytic oxidation (PEO) is applied to a metal base
Implementation Method 2
In the process a pulsed voltage is passed through a bath of electrolyte solution and applied to the substrate
Implementation Method 3
The substrate includes heat sinks and a power transformer is mounted directly on the heat sink
Data Source
AI summary
An electrical power substrate comprises a metallic body at least one surface of the body having a coating generated by plasma electrolytic oxidation (PEO). The coating includes a dense hard layer adjacent the said surface of the metallic body, and a porous outer layer. Electrically conductive elements are attached to the said coating.