Composite member and method of manufacturing composite member

Patent metadata

Field	Value
Publication number	US-2021002769-A1
Application number	US-201916969238-A
Country	US
Kind code	A1
Filing date	Jan 30, 2019
Priority date	Feb 14, 2018
Publication date	Jan 7, 2021
Grant date	—

Abstract

A composite member includes: a substrate formed of a composite material containing a plurality of diamond grains and a metal phase; and a coating layer made of metal. The surface of the substrate includes a surface of the metal phase, and a protrusion formed of a part of at least one diamond grain of the diamond grains and protruding from the surface of the metal phase. In a plan view, the coating layer includes a metal coating portion, and a grain coating portion. A ratio of a thickness of the grain coating portion to a thickness of the metal coating portion is equal to or less than 0.80. The coating layer has a surface roughness as an arithmetic mean roughness Ra of less than 2.0 μm.

First claim

1 . A composite member comprising:
a substrate formed of a composite material containing
a plurality of diamond grains, and
a metal phase that bonds the diamond grains; and
a coating layer made of metal and coating at least a part of a surface of the substrate, wherein the surface of the substrate includes
a surface of the metal phase, and
a protrusion formed of a part of at least one diamond grain of the diamond grains and protruding from the surface of the metal phase,
in a plan view, the coating layer includes
a metal coating portion coating the surface of the metal phase, and
a grain coating portion coating the protrusion and not coating the surface of the metal phase,
a ratio of a thickness of the grain coating portion to a thickness of the metal coating portion is equal to or less than 0.80, and the coating layer has a surface roughness as an arithmetic mean roughness Ra of less than 2.0 μm.

2 . The composite member according to claim 1 , wherein
metal that forms the metal phase is silver or a silver alloy.

3 . The composite member according to claim 1 , wherein
the metal that forms the coating layer is a nickel alloy containing phosphorus.

4 . A method of manufacturing a composite member, the method comprising:
etching a surface of a material plate formed of a composite material containing a plurality of diamond grains and a metal phase that bonds the diamond grains, to produce a rough surface plate in which a part of at least one diamond grain of the diamond grains protrudes from a surface of the metal phase; subjecting the rough surface plate to first electroless plating to produce a partial coating plate in which a first plating layer is formed on the surface of the metal phase while exposing a part of at least one diamond grain of the diamond grains existing on the surface of the material plate; and subjecting the partial coating plate to second electroless plating to form a second plating layer that coats
a surface of the first plating layer and
a portion of at least one diamond grain of the diamond grains that is exposed from the surface of the first plating layer.

Assignees

• Sumitomo Electric Industries
• Almt Corp

Inventors

• Goto Kengo
• Ikeda Tomoaki
• Hosoe Akihisa
• Sugisawa Masanori
• Ishikawa Fukuto
• Morigami Hideaki

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

• H10W40/258 Primary

  Metallic materials (H10W40/254, H10W40/257, H10W40/255, H10W40/251, H10W40/253 take precedence) · CPC title

• H10W40/254

  Diamond · CPC title

• C22C1/05

  Mixtures of metal powder with non-metallic powder (C22C1/08 takes precedence) · CPC title

• Y10T428/12993

  Surface feature [e.g., rough, mirror] · CPC title