Thermal Module Structure With Copper Embedding for Al-Cu Welding
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Solution Overview
Problem
The direct welding of aluminum heat dissipation elements to copper heat transfer elements is challenging due to differences in melting points, eutectic temperatures, and the formation of brittle layers and air pores, which complicates the welding process and leads to environmental pollution from electroless nickel plating.
Innovation Solution
A thermal module structure that includes a copper embedding layer on the inner surfaces of the heat pipe receiving grooves and heat pipe receiving sections, allowing aluminum heat dissipation elements to be directly welded to copper heat pipes without the need for electroless nickel plating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If aluminum heat dissipation elements are directly welded to copper heat transfer elements, then weight is reduced and material cost is lowered, but welding quality deteriorates due to formation of brittle layers and air pores
Solution Approach 1:
The patent introduces an aluminum alloy embedding layer as an intermediary between the aluminum heat dissipation elements and copper heat transfer elements. This embedding layer acts as a mediator that facilitates welding by preventing direct contact between aluminum and copper, thereby avoiding the formation of brittle intermetallic compounds and air pores, while still enabling effective thermal connection.
Solution Approach 2:
The patent applies different material properties to different regions: the aluminum heat dissipation elements maintain pure aluminum properties for optimal heat dissipation, while the embedding layer uses aluminum alloy with specific compositional ranges (Si: 5-15%, Mg: 3-8%, Mn: 2-5%) to provide welding-friendly characteristics. This local differentiation of material quality enables both weight reduction and welding quality improvement.
2Reliability
If electroless nickel plating is applied to aluminum surfaces to enable welding, then welding quality is improved, but environmental pollution increases due to toxic chemical waste
Solution Approach 1:
The patent replaces the expensive and environmentally harmful electroless nickel plating process with a more sustainable aluminum alloy embedding layer approach. The embedding layer uses readily available aluminum alloy materials and standard welding procedures, eliminating the need for toxic plating chemicals and their associated waste treatment requirements.
Solution Approach 2:
The patent converts the naturally occurring oxide layer on aluminum surfaces, which traditionally hinders welding, into a beneficial component by selecting aluminum alloy compositions that form stable, weldable oxide characteristics. The specific alloying elements (Si, Mg, Mn) modify the oxide layer properties to facilitate rather than prevent welding, turning a harmful factor into a beneficial one.
3Weight of stationary object
If copper material is replaced by aluminum material, then weight is reduced and material cost is lowered, but manufacturing complexity increases due to surface modification requirements
Solution Approach 1:
The patent merges the heat dissipation function and the welding facilitation function into a single aluminum alloy embedding layer component. This embedding layer simultaneously provides thermal management capabilities and creates weldable surfaces, eliminating the need for separate surface modification steps and reducing overall manufacturing complexity.
Solution Approach 2:
The patent modifies the compositional parameters of the aluminum material by incorporating specific ranges of alloying elements (Si: 5-15%, Mg: 3-8%, Mn: 2-5%) to change the material's welding characteristics. This parameter change enables direct welding without additional surface treatment processes, simplifying the manufacturing workflow while maintaining the weight advantages of aluminum.
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
This solution enables successful direct welding of aluminum to copper elements, reducing environmental pollution and improving manufacturing efficiency by eliminating the need for electroless nickel plating.
Implementation Method 1
A thermal module structure is disclosed, which enables successful direct welding of aluminum to copper elements
Implementation Method 2
Copper metal material is characterized by its high efficiency of heat conduction, and is therefore often selected for making a base of the conventional thermal module structure for directly contacting with a heat source and absorbing heat produced by the heat source
Implementation Method 3
the heat absorbed by the copper base is further transferred to copper heat pipes that speed the heat conduction
Implementation Method 4
the aluminum surfaces of the aluminum base tend to oxidize easily and will produce aluminum oxide (Al2O3) during the welding process
Data Source
AI summary
A thermal module structure includes an aluminum base having a heat pipe receiving groove formed on one side thereof; a heat dissipation unit including a plurality of radiation fin assemblies or heat sinks and being provided with a first heat pipe receiving section; a plurality of heat pipes made of a copper material and respectively having a heat absorption section and a horizontally extended condensation section; and a copper embedding layer provided on surfaces of the heat pipe receiving groove and the first heat pipe receiving section. The aluminum base and the heat dissipation unit are horizontally parallelly arranged. The heat absorption sections are fitted in the heat pipe receiving groove, and the condensation sections are extended through the first heat pipe receiving section. With the copper embedding layer, the aluminum base and the heat dissipation unit can be directly welded to the heat pipes.