Thermal Module Structure With Copper Embedding Weld Interface
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Solution Overview
Problem
The direct welding of copper and aluminum metal materials is hindered by the formation of aluminum oxide, brittleness, and differences in melting points, leading to difficulties in forming strong bonds without surface modification.
Innovation Solution
The use of copper embedding layers on the aluminum base and other components allows for direct welding of dissimilar metal materials, such as copper heat pipes and aluminum bases, without the need for electroless nickel plating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electroless nickel plating is applied to aluminum surfaces before welding, then welding between aluminum and copper becomes feasible, but manufacturing cost increases and environmental pollution occurs due to toxic chemicals
Solution Approach 1:
The invention extracts and removes the electroless nickel plating process from the manufacturing flow. Instead of plating aluminum surfaces with nickel before welding, the patent directly welds aluminum to copper after simple surface treatment, eliminating the need for toxic chemicals and complex plating equipment while maintaining welding quality
Solution Approach 2:
The invention introduces a copper embedding layer as an intermediary between aluminum and copper components. This copper layer serves as a transition zone that facilitates welding between dissimilar metals without requiring nickel plating, thereby reducing manufacturing complexity and environmental impact
2Ease of manufacture
If direct welding is attempted between aluminum and copper without surface modification, then manufacturing cost is reduced, but welding fails due to aluminum oxide formation and brittleness
Solution Approach 1:
The invention performs preliminary surface treatment of aluminum surfaces before welding, including removal of aluminum oxide layers and application of copper embedding layers. This preliminary preparation enables subsequent direct welding without requiring expensive and environmentally harmful nickel plating
Solution Approach 2:
The copper embedding layer acts as an intermediary substance that bridges aluminum and copper materials. It is applied to aluminum surfaces before welding, creating a transition zone that allows successful welding between dissimilar metals while avoiding the need for nickel plating
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 approach enables cost-effective manufacturing while ensuring environmental protection by eliminating the use of toxic chemicals associated with electroless nickel plating, and addresses material shortages and bonding issues.
Implementation Method 1
the aluminum fin assembly and the copper heat pipe made of dissimilar metal materials all can be directly connected to the aluminum base by welding without the need of electroless nickel plating
Implementation Method 2
The copper heat pipes respectively have a heat absorption end received in a groove sunken into a lower surface of the aluminum base, and a heat dissipation end extended from the heat absorption end
Implementation Method 3
copper metal material has the feature of high efficiency of heat conduction, it is often selected for making a heat dissipation base of the heat sink or the heat dissipation device to exchange heat with heat-producing execution units
Data Source
AI summary
A thermal module structure includes an aluminum base having an upper and a lower surface, at least one L-shaped copper heat pipe, a first aluminum fin assembly, a second aluminum fin assembly, and at least one copper embedding layer. The copper heat pipe includes a heat absorption section fitted on the aluminum base, and a heat dissipation section connected to the second aluminum fin assembly. The copper embedding layers are provided on the aluminum base at areas corresponding to the first aluminum fin assembly and the heat absorption section of the copper heat pipe, and on a bottom surface of the first aluminum fin assembly that is to be connected to the aluminum base. Thus, the first aluminum fin assembly and the copper heat pipe can be directly welded to the aluminum base via the copper embedding layers without the need of electroless nickel plating.