Production method for aluminum-diamond composite

Patent metadata

Field	Value
Publication number	US-12303973-B2
Application number	US-202218562539-A
Country	US
Kind code	B2
Filing date	May 16, 2022
Priority date	May 26, 2021
Publication date	May 20, 2025
Grant date	May 20, 2025

Abstract

A production method for an aluminum-diamond composite having a step of providing a laminate structure including a composition layer containing a diamond powder in an opening of a flat plate-like porous material having the opening so as to be separated from an inner circumferential surface of the opening and a step of press-fitting a melt of a metal containing aluminum into a space between the porous material and the laminate structure and impregnating the composition layer with the melt to form a composited part containing aluminum and diamond and forming metal layers on at least side surfaces of the laminate structure, in which the laminate structure includes a first mold release plate, a first inorganic layer, the composition layer, a second inorganic layer and a second mold release plate in this order.

First claim

The invention claimed is:

1. A production method for an aluminum-diamond composite comprising:
providing a laminate structure, comprised of a first mold release plate, a first inorganic layer, a composition layer containing a diamond powder, a second inorganic layer, and a second mold release plate in this order, in an opening of a flat plate porous material having the opening so that side surfaces of the laminate structure are separated by a gap from an inner circumferential surface of the flat plate porous material; and
infiltrating a melt of a metal containing aluminum into the porous material and the laminate structure to impregnate the composition layer with the melt, the infiltrating forming in the same infiltrating step each of (a) a composited part containing aluminum and diamond from the composition layer, (b) a metal-containing layer on each of two main surfaces on opposite sides of the composited part, and (c) metal layers on at least side surfaces of the composited part where the gap between the laminate structure and the inner circumferential surface of the porous material had been located,
wherein the aluminum-diamond composite comprises the composited part containing aluminum and diamond as a flat plate, the metal-containing layers provided on each of the two main surfaces on opposite sides of the composited part, and the metal layers provided on side surfaces of the composited part.

2. The production method according to claim 1 ,
wherein the opening is a through hole that penetrates in a vertical direction.

3. The production method according to claim 1 ,
wherein the opening is a recessed part.

4. The production method according to claim 1 ,
wherein the first inorganic layer is at least one of an inorganic fiber-containing layer and a metal foil containing aluminum.

5. The production method according to claim 1 ,
wherein the second inorganic layer is at least one of an inorganic fiber-containing layer and a metal foil containing aluminum.

6. The production method according to claim 1 ,
wherein the gap comprises a distance between the inner circumferential surface of the porous material and the laminate structure, and is 0.05 to 3.50 mm.

7. The production method according to claim 1 , further comprising:
following the infiltrating, adjusting an average thickness of the metal layers.

8. The production method according to claim 1 ,
wherein the infiltrating of the melt is performed by a cast forging process.

9. The production method according to claim 1 ,
wherein a content of aluminum in the melt is 80 mass % or more.

10. The production method according to claim 1 ,
wherein an average thickness of the metal layers is 0.01 to 3.00 mm.

11. The production method according to claim 10 ,
wherein surfaces of the metal-containing layers and the metal layers opposite to the composited part are smooth surfaces.

12. The production method according to claim 11 ,
wherein surface roughness Ra in the smooth surfaces is 0.5 to 1.0 μm.

13. The production method according to claim 10 ,
wherein an average thickness of the metal-containing layers is 0.01 to 0.20 mm.

Assignees

• Denka Company Ltd

Inventors

• Ota Hiroaki
• Ishihara Yosuke
• Goto Daisuke

Classifications

• H10W70/02

  of conductive package substrates serving as an interconnection, e.g. of metal plates (manufacture or treatment of leadframes H10W70/04) · CPC title

• H10W40/257

  having a heterogeneous or anisotropic structure, e.g. powder or fibres in a matrix, wire mesh or porous structures (H10W40/254, H10W40/251 take precedence) · CPC title

• C22C26/00

  Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes} · CPC title

• B22D18/02 Primary

  Pressure casting making use of mechanical pressure devices, e.g. cast-forging (B22D18/04 takes precedence) · CPC title

• C22C1/1073

  Infiltration or casting under mechanical pressure, e.g. squeeze casting · CPC title