Segmented Aluminum Base Plate for Power Module Thermal Management
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Solution Overview
Problem
Existing base plates for power modules have limited ability to adapt to the topography of heat sinks, leading to thermal insulation cavities and a risk of cracking due to internal tension, which reduces heat dissipation and durability.
Innovation Solution
A base plate with a matrix of ductile metal, such as aluminum, and embedded, spaced-apart ceramic reinforcements that act as independent heat spreaders, allowing for flexible adaptation to the heat sink surface and reducing internal stress, thereby enhancing heat transfer and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a base plate with continuous reinforcement structure is used to reduce thermal insulation cavities, then heat dissipation is improved, but internal tension increases causing cracking risk
Solution Approach 1:
The base plate structure is segmented into a matrix body and multiple separated plate-shaped reinforcements. The reinforcements are spaced apart rather than continuous, which reduces internal tension and cracking risk while still effectively bridging thermal insulation cavities to improve heat dissipation.
2Area of stationary object
If a base plate with convex bow is used to reduce gap between base plate and heat sink, then contact area is improved, but adaptability to heat sink topography is limited
Solution Approach 1:
The base plate incorporates localized plate-shaped reinforcements that can independently adapt to local variations in heat sink surface topography. These separated reinforcements provide local contact points that conform to surface irregularities while the overall base plate structure remains flexible.
3Loss of energy
If internal tension is applied to secure base plate to heat sink, then heat dissipation properties are improved, but base plate cracking risk increases
Solution Approach 1:
The segmented reinforcement structure distributes mechanical stresses more evenly throughout the base plate. The spaced-apart plate-shaped reinforcements act as independent load-bearing elements that reduce stress concentration, allowing the base plate to maintain structural integrity even when secured to the heat sink with necessary tension for optimal heat dissipation.
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 improves heat dissipation by minimizing thermal insulation cavities and reduces the risk of cracking, ensuring stable and efficient thermal management while maintaining the structural integrity of the base plate.
Implementation Method 1
The reinforcements are spaced apart from each other and are plate-shaped... act as a heat spreader to extract the heat from the power module... to the heat sink
Data Source
Figure 1~2
Figure 3~4
Figure 5~6b
AI summary
The present invention relates to a base plate (34), in particular for a power module (10), comprising a matrix (38) formed of metal, in particular of aluminium, wherein at least two reinforcements (42) are provided in said matrix (38) next to each other, and wherein the reinforcements (42) are spaced apart from each other. Base plates (34) according to the invention enable an improved contact between the base plate (34) and a heat sink (36) and furthermore provide enhanced durability properties.