JP2020011278A - Composite body and method for manufacturing the same - Google Patents

Abstract

To provide a composite body 1 comprising a copper plate 3 and an aluminum body 4 that can reduce the number of manufacturing processes and manufacturing cost and realize a well adhesion between the copper plate 3 and the aluminum body 4, and a method for manufacturing the same.SOLUTION: The composite body 1 comprises the copper plate 3 and the aluminum body 4 joined to the copper plate 3. The copper plate 3 has at least one of a groove 5, a penetration hole 6 and a non-penetration hole 7, in a copper plate surface 8 of the copper plate 3 that is a surface to which the aluminum body 4 is joined. The aluminum body 4 is configured having a mating protrusion 9 to be fit in the groove 5, the penetration hole 6 or the non-penetration hole 7. By cast-coating the copper plate 3 over the aluminum body 4, the copper plate 3 and the aluminum body 4 are joined together, thereby manufacturing the composite body 1.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a composite manufactured by a casting method utilizing a cast-in and a manufacturing method thereof.

  2. Description of the Related Art Conventionally, a heat sink has been proposed in which an aluminum heat sink including pure aluminum and an aluminum alloy is combined with a copper plate using copper having a thermal conductivity approximately twice that of aluminum. For example, in Patent Literatures 1 and 2, a copper plate is surface-bonded to a base plate of an aluminum heat sink or an aluminum fin by soldering. In Patent Document 3, a composite plate in which an interface between a copper plate and an aluminum plate is metal-bonded is formed, and a radiation fin made of aluminum is provided on the surface of the aluminum plate of the composite plate.

JP-A-2002-237557 JP-A-2002-324880 JP-A-9-298259

  In the heat sinks of Patent Literatures 1 and 2, heat generated by a non-cooled object, for example, a semiconductor chip or the like is transmitted in a plane of a copper plate having high thermal conductivity, so that heat radiation can be improved. However, since it is necessary to join the copper plate and the aluminum base plate or fin by soldering, the number of manufacturing steps increases and the manufacturing cost also increases. In addition, there is a problem that the heat resistance increases due to the presence of the solder, and the heat of the uncooled material cannot be efficiently transmitted from the copper plate to the aluminum, so that heat cannot be effectively radiated to the outside.

  Also in the heat sink of Patent Document 3, the fin of the heat sink must be formed after the aluminum plate and the copper plate are joined, and there is a problem that the increase in the number of manufacturing steps and the accompanying increase in the manufacturing cost cannot be solved.

  Conventionally, a technique of casting a copper material with aluminum has been proposed.However, due to a problem that aluminum is separated from the copper material due to thermal stress during casting, a high adhesion between the copper material and the aluminum is required. It has been difficult to produce a heat sink having the same by casting.

  The present invention has been made in view of such circumstances, and is to cast a copper plate having at least one of a groove, a through hole, and a non-through hole with a casting metal that is a raw material of an aluminum body. The present invention provides a composite which can reduce the number of manufacturing steps and manufacturing cost, and can realize high adhesion between a copper plate and an aluminum body, and a method for manufacturing the same.

  In order to solve the problem, the present invention includes a copper plate and an aluminum body joined to the copper plate, wherein the copper plate has grooves, through holes and non-penetrations on a surface of the copper plate to which the aluminum body is joined. A composite having at least one of the holes, wherein the aluminum body has a fitting protrusion that fits into the groove, the through hole, or the non-through hole.

  In the composite, the groove has an inverted tapered shape in which a width decreases toward the copper plate surface, and the through-hole and the non-through hole have a cross-sectional area of a cross section parallel to the copper plate surface toward the copper plate surface. May have an inversely tapered shape in which

  In the composite, a reaction layer of copper of the copper plate and a metal constituting the aluminum body may be provided between the copper plate and the aluminum body.

  In the composite, the aluminum body may have a plurality of corrugated fins.

  In the composite, the composite may be a heat sink.

  The present invention includes a step of inserting a copper plate having at least one of a groove, a through hole and a non-through hole into a mold, and melting a metal as a raw material of an aluminum body to be joined to the copper plate with a molten metal of the mold. Filling the inside and casting the copper plate in the aluminum body. A method for producing a composite of the copper plate and the aluminum body.

  In the method of manufacturing the composite, the groove has a reverse tapered shape in which a width decreases toward a copper plate surface of the copper plate, which is a surface to be joined to the aluminum body, and the through hole and the non-through hole are formed of the aluminum. The copper plate may have a reverse tapered shape in which a cross-sectional area of a cross section parallel to the copper plate surface decreases toward a copper plate surface of the copper plate which is a surface to be joined to a body.

  In the method of manufacturing the composite, a plating layer may be formed on a surface of the copper plate, which is a surface to be joined to the aluminum body of the copper plate.

  In the method of manufacturing the composite, the plating layer may be an electroless nickel plating layer.

  In the method of manufacturing a composite, the mold may be configured to form a plurality of corrugated fins on the aluminum body.

  In the method of manufacturing the composite, the composite may be a heat sink.

  According to the composite of the present invention and the method for producing the same, the number of production steps and the production cost are reduced, the adhesion between the copper plate and the aluminum body is increased, and a composite applicable to, for example, a heat sink having high heat dissipation is realized. it can.

It is a schematic diagram of a side section of a composite concerning an embodiment of the present invention. It is the perspective photograph figure which looked at the composite (heat sink) concerning the embodiment of the present invention from the bottom side (the copper plate side). It is the perspective photograph figure which looked at the composite (heat sink) concerning the embodiment of the present invention from the upper part (the aluminum body side). It is a top view which shows an example of the lattice-shaped groove | channel formed in the surface of the copper plate concerning embodiment of this invention. It is a top view which shows an example of the cross-shaped groove | channel formed in the surface of the copper plate concerning embodiment of this invention. It is EE sectional drawing of FIG.4 and FIG.5 which shows the groove | channel of the reverse taper shape formed in the surface of the copper plate which concerns on embodiment of this invention. It is a photograph of the side section which expands and shows the mode that the fitting projection part of the aluminum body (made of aluminum alloy) fits into the groove of the copper plate concerning the embodiment of the present invention. It is a top view which shows an example of the through-hole and the non-through-hole formed in the surface of the copper plate concerning embodiment of this invention. FIG. 9 is a cross-sectional view taken along the line AA of FIG. 8 illustrating an example of a reverse tapered through hole formed in the surface of the copper plate according to the embodiment of the present invention. It is a photograph figure of the side section of the compound (heat sink) which formed the through-hole in the surface of the copper plate concerning the embodiment of the present invention, and cast the copper plate with the metal (aluminum alloy) for casting. It is a photograph of the side section which expands and shows the mode that the fitting projection part of the aluminum body (made of an aluminum alloy) fits into the through-hole of the copper plate which concerns on embodiment of this invention. FIG. 9 is a cross-sectional view taken along the line AA of FIG. 8 illustrating an example of a non-through hole having an inverted taper shape formed on the surface of the copper plate according to the embodiment of the present invention. It is a photograph figure which expands and shows the side cross section of the joining surface of the copper plate and aluminum body (made of an aluminum alloy) which concern on embodiment of this invention. It is the bottom surface photograph figure which looked at the composite produced by forming a slot in the surface of the copper plate concerning the embodiment of the present invention from the copper plate side. It is a schematic diagram of a side section of a composite having a plating layer according to an embodiment of the present invention. FIG. 2 is a side sectional view showing a mold for producing a composite according to the embodiment of the present invention. It is a side sectional view showing signs that a metallic mold concerning an embodiment of the present invention is opened and a copper plate is inserted in a movable metallic mold. FIG. 4 is a side sectional view showing a state of a mold clamping operation of the mold according to the embodiment of the present invention. It is a sectional side view showing signs that a metallic mold concerning an embodiment of the present invention was made into a mold clamped state. It is a sectional side view showing signs that casting metal is cast into a metallic mold concerning an embodiment of the present invention. It is a sectional side view showing signs that a metallic mold concerning an embodiment of the present invention was made to open a metallic mold after cooling. It is a sectional side view showing signs that a product is extruded from a metallic mold concerning an embodiment of the present invention. FIG. 3 is a side sectional view showing a die-cast product extruded from a mold according to an embodiment of the present invention and separated from a casting plan. It is a flowchart which shows the flow of a procedure from insertion of the copper plate to the movable die to extrusion of the product which concerns on embodiment of this invention.

  Hereinafter, preferred embodiments of a composite according to the present invention and a method for producing the same will be described with reference to the drawings.

  FIG. 1 shows a side sectional view of the composite 1, and FIG. 2 shows a photograph of the composite 1 of the present embodiment. The composite 1 includes a copper plate 3 and an aluminum body 4 joined to the copper plate 3.

  The raw material of the copper plate 3 is, for example, pure copper or a copper alloy. The copper plate 3 is, for example, a flat plate made of these raw materials. The raw material of the aluminum body 4 is, for example, pure aluminum or an aluminum alloy. The aluminum body 4 is a metal body manufactured by using these materials and molding by casting. The shape of the aluminum body 4 is not particularly limited, but may be, for example, a flat plate or a heat sink having fins. Aluminum alloys include pure aluminum, such as silicon (Si), copper (Cu), magnesium (Mg), and nickel (Ni), such as aluminum-silicon alloys, aluminum-copper-silicon alloys, and aluminum-magnesium alloys. ), Manganese (Mn), zinc (Zn) and other metal elements. By using an aluminum alloy of a high thermal conductive material as a raw material of the aluminum body 4, the heat sink 2 can be attached to a non-cooled object (not shown) by brazing. The composite 1 of the present embodiment can be manufactured by joining the copper plate 3 and the aluminum body 4 by casting the copper plate 3 in the aluminum body 4.

  In the present embodiment, an application example in which the composite 1 is a heat sink 2 will be described. In FIG. 2, the aluminum body 4 constituting the heat sink 2 has a plurality of fins 11 having a height in the vertical direction from the aluminum body 4, but has a flat shape without the fins 11 as shown in FIG. You can also. The fin 11 may have a corrugated shape as shown in FIG. 3 or a rectangular shape. When the fins 11 have a corrugated shape, the average flow velocity of the fluid passing between the fins 11 can be improved and the cooling efficiency can be increased as compared with the case of a rectangular shape.

  The copper plate 3 has at least one of a groove 5, a through hole 6, and a non-through hole 7 on a copper plate surface 8 to which the aluminum body 4 is bonded. 4 and 5 show examples of forming the groove 5. FIG. In FIG. 4, grooves 5 are formed in a grid pattern on the copper plate surface 8 of the copper plate 3. In FIG. 5, a cross-shaped groove 5 is dug in the copper plate surface 8 of the copper plate 3, and a groove is dug in a diagonal line of the copper plate 3. The groove 5 can be dug by machining. As shown in FIG. 1, the fitting protrusion 9 of the aluminum body 4 is fitted into the groove 5. Thereby, the aluminum body 4 is mechanically connected to the copper plate 3, and high bonding force and high adhesion between the copper plate 3 and the aluminum body 4 can be realized. The same applies to the through hole 6 shown in FIG. 9 and the non-through hole 7 shown in FIG.

  FIG. 6 shows an example of a side sectional view of the groove 5 (a sectional view taken along line EE in FIGS. 4 and 5). The groove 5 has a predetermined depth in the thickness direction of the copper plate 3. The depth of the groove 5 is not particularly limited, and can be made relatively shallow, for example, from the copper plate surface 8 to 1/4 of the thickness of the copper plate 3, or relatively deep, up to 3/4. . For example, in FIG. 6, the groove 5 has a half depth with respect to the thickness direction of the copper plate 3. The width of the groove 5 can be constant in the thickness direction of the copper plate 3. On the other hand, as shown in FIG. 6, the groove 3 may have an inverted taper shape in which the width becomes narrower toward the copper plate surface 8 with the aluminum body 4 (upward in the figure). Since the groove 5 has the reverse tapered shape, the fitting projection 9 of the aluminum body 4 fitted in the groove 5 is prevented from coming off from the groove 5 as shown in FIG. It is possible to realize a further high bonding force and a high adhesion with the body 4. The angle of the reverse taper can be appropriately set, for example, so that the tapered side surface 16 has an angle α with respect to a perpendicular P to the copper plate 3. The angle α is not particularly limited, but is preferably 1 ° to 10 °, more preferably 3 ° to 8 °, and further preferably 4 ° to 6 °.

  FIG. 7 is an enlarged cross-sectional photograph showing a cut surface near the groove 5 of the actually manufactured heat sink 2. In the figure, a groove 5 having a depth of 1 mm is dug into a copper plate 3 having a thickness of 2 mm, and the width of the groove 5 is set to 3 mm at the largest portion. The reverse taper angle α was 5 °. The fitting protrusion 9 of the aluminum plate, which is the aluminum body 4, is fitted into the groove 5 formed in the copper plate 3 without any gap, and there is no gap or peeling off at the joint surface 10 between the copper plate 3 and the aluminum body 4, so that it is in close contact. Can be confirmed to be high.

  In FIG. 8, a through hole 6 penetrating in the thickness direction of the copper plate 3 is formed in the copper plate surface 8 of the copper plate 3. The through holes 6 can be formed by machining. In the figure, a total of twelve through holes 6 are formed, which are regularly arranged in three rows in the vertical direction and four rows in the horizontal direction. The number and the distance between the adjacent through holes 6 are not limited. For example, the through holes 6 may be formed only near the four corners of the copper plate 3, or the through holes 6 may be formed in the center of the copper plate 3. The cross-sectional area of the cross section of the through hole 6 parallel to the copper plate surface 8 can be constant in the thickness direction of the copper plate 3. On the other hand, as shown in the side sectional view of FIG. 9 (sectional view taken along the line AA of FIG. 8), the through hole 6 faces the copper plate surface 8 of the copper plate 3 which is the surface to be joined to the aluminum body 4 (FIG. 9). May have an inverted tapered shape in which the cross-sectional area decreases. Since the through-hole 6 has the reverse tapered shape, the fitting protrusion 9 of the aluminum body 4 fitted in the through-hole 6 is prevented from coming out of the through-hole 6, and the copper plate 3 and the aluminum body 4 Further, high bonding strength and high adhesion can be maintained. The angle β of the reverse taper is not particularly limited, but is preferably 2 ° to 20 °, more preferably 6 ° to 16 °, and further preferably 8 ° to 12 °. The shape of the through hole 6 is not limited to a circle, but may be, for example, a polygon.

  FIG. 10 is a photograph of the heat sink 2 actually manufactured. In the figure, the maximum diameter of the through hole 6 is set to 3 mm and the angle β of the reverse taper is set to 10 ° for the copper plate 3 having a thickness of 2 mm. The fitting protrusion 9 of the aluminum body 4 is fitted in the through hole 6 formed in the copper plate 4. FIG. 11 is a cross-sectional photographic view in which a cut surface showing the vicinity of the through hole 6 is enlarged. The fitting projection 9 of the aluminum body 4 is fitted into the through-hole 6 formed in the copper plate 4 without any gap, and there is no gap or separation between the copper plate 3 and the aluminum body 4, and the adhesion is high. You can check.

  As shown in the side sectional view of FIG. 12 (the sectional view taken along the line AA of FIG. 8), the non-through hole 7 can be formed in the copper plate 4. The non-through hole 7 can be dug by machining. A top view showing an example of the non-through hole 7 is the same as FIG. The non-through hole 7 has a predetermined depth in the thickness direction of the copper plate 3. As in the case of the above-described groove 5, the depth of the non-through-hole 7 can be appropriately set. Similarly to the through-hole 6, the cross-sectional area of the non-through-hole 7 may be constant in the thickness direction of the copper plate 3, or may be toward the copper plate surface 8 of the copper plate 3, which is the surface to be joined to the aluminum body 4 (FIG. 12). May have an inverted tapered shape in which the cross-sectional area decreases. The angle γ of the reverse taper is not particularly limited, but is preferably 2 ° to 20 °, more preferably 6 ° to 16 °, and further preferably 8 ° to 12 °. The arrangement, the number, and the shape of the non-through holes 7 can be appropriately set similarly to the through holes 6.

  FIG. 13 is a cross-sectional photographic view in which a cut surface showing the joint surface 10 between the copper plate 3 and the aluminum body 4 is enlarged. Reference numeral 13 denotes a reaction layer between copper and an aluminum alloy constituting the aluminum body 4. A reaction layer 13 between the copper of the copper plate 3 and the metal 20 constituting the aluminum body 4 is provided between the copper plate 3 and the aluminum body 4. Are formed. By forming the reaction layer 13, the bonding surface 10 between the copper plate 3 and the aluminum body 4 has high bonding and adhesion. Further, from the figure, it can be confirmed that there is no gap or separated portion on the bonding surface 10.

  When the groove 5 is formed in the copper plate 3, as shown in FIG. 14, the surface 15 of the copper plate 3 that contacts the non-cooled object (not shown) can be easily made a flat surface. The heat spreads efficiently and is preferable. The same applies to the case of the non-through hole 7. On the other hand, in the case of the through-hole 6, the surface 19 of the fitting projection 9 of the aluminum body 4 is exposed on the surface 18 of the copper plate 3 as shown in FIG. The surface 18 of the copper plate 3 and the surface 19 of the fitting projection 9 can be made flush with each other by adjusting conditions such as pressure and / or devising the shape of the mold.

  Before casting the copper plate 3 in the aluminum body 4, a plating layer 14 may be formed between the copper plate 3 and the aluminum body 4. By forming the plating layer 14, the adhesion between the copper plate 3 and the aluminum body 4 can be further improved. The plating layer 14 may be formed only on the copper plate surface 8 which is the surface to be joined to the aluminum body 4 of the copper plate 3, or may be formed on the entire surface of the copper plate 3. The plating layer 14 may be formed before forming the groove 5, the through hole 6, and the non-through hole 7, or may be formed after forming the groove 5, the through hole 6, and the non-through hole 7. Even if the plating layer 14 is formed, the reaction layer 13 of the copper of the copper plate 3 and the metal 20 constituting the aluminum body 4 may be formed as described above because the thickness of the plating layer 14 is small. The reaction layer 13 may include plating of the plating layer.

  The plating layer 14 may be formed beforehand on the surface of the copper plate 3 and / or the aluminum body 4 before casting the copper plate 3 on the aluminum body 4. There is no need for 14 to remain. As shown in FIG. 15, the plating layer 14 may remain between the joined copper plate 3 and the aluminum body 4 in some cases. The bonding between the copper plate 3 and the aluminum body 4 includes the case where the plating layer 14 remains and the plating layer 14 exists between the copper plate 3 and the aluminum body 4. The plating layer 14 can be, for example, an electroless nickel plating layer.

  In the manufacturing method for manufacturing the composite 1 and the heat sink 2 of the present embodiment, the copper plate 3 having at least one of the groove 5, the through hole 6, and the non-through hole 7 in the aluminum body 4 can be cast. The method is not particularly limited as long as it can be performed. Hereinafter, a manufacturing method using high-pressure die casting will be described as an example.

  FIG. 16 shows a mold 21 for manufacturing the composite 1 and the heat sink 2 of the present embodiment. The mold 21 includes a fixed mold 23 and a movable mold 24 that are combined with each other during casting. The fixed mold 23 and the movable mold 24 can be manufactured using, for example, SKD61 or the like as a material. A cylindrical injection sleeve 26 is connected so as to communicate with the product part 34 in the mold 21.

  Referring to FIG. 16, the mold 21 is opposed to the fixed mold 23, the movable mold 24 combined with the fixed mold 23 during casting, and the fixed mold 23 when the movable mold 24 is combined with the fixed mold 23. On the surface of the movable mold 24, a copper plate insertion portion 51 formed by being dug into a predetermined shape so as to match the shape of the copper plate 3, and a runner portion 32 formed by being dug by the movable mold 24 so as to extend from the biscuit portion 31. And a gate unit 33. The copper plate insertion part 51 may be formed on the fixed die 23.

  17 to 23 are side sectional views showing a state from insertion of the copper plate 3 into the movable mold 24 to extrusion of the product 44.

  As shown in the side sectional views of FIGS. 17 to 19, the movable mold 24 is freely movable between a mold clamping position combined with the fixed mold 23 and a mold open position separated from the fixed mold 23. The movable mold 24 is movable leftward in the figure so as to be separated from the fixed mold 23, and is movable rightward so as to approach. The grooves 5 and the through holes 6 are shown on the copper plate 3 of FIGS. 17 to 23 for convenience.

  As shown in FIGS. 20 to 22, the casting scheme 40 includes a biscuit 41 connected to a product 44, a runner 42, a gate 43, and an overflow 45. Here, the biscuit 41, the runner 42, the gate 43, the product 44, and the overflow 45 respectively correspond to the biscuit part 31, the runner part 32, the gate part 33, the product part 34, and the overflow part 35 formed in the mold 21 shown in FIG. And the molten metal 39 solidified. The casting plan 40 is necessary only at the time of casting, and is an unnecessary part for the final product. Therefore, the casting method 40 is separated from the product 44 to complete the die-cast product 46 shown in FIG. In the present embodiment, the product connected to the casting plan 40 is referred to as a product 44, and the product obtained by separating the casting plan 40 is referred to as a die-cast product 46. In this embodiment, the die-cast product 46 becomes the composite 1 such as the heat sink 2.

  The fixed mold 23 is provided with an injection sleeve 26 and a plunger tip (not shown) slidable in the injection sleeve 26, and a molten metal 39 is injected into the injection sleeve 26 from an opening (not shown). Configured as possible.

  The product part 34 is an internal space in which the product 44 is cast, and has a dug surface (not shown) corresponding to a desired product shape such as the heat sink 2 having the corrugated fins 11.

  The fixed die 23 has a product forming surface 56 that forms an internal space (cavity) 52 as a product part 34 that is a space filled with the molten metal 39 when the molten metal 39 is injected in combination with the movable die 24. When the product forming surface 56 of the fixed mold 23 and the movable mold 24 approach each other, the product part 34 inside the mold 21 is formed. The copper plate 3 is inserted into the copper plate insertion portion 51 of the movable mold 24. When the movable mold 24 moves closer to the fixed mold 23 when the mold 21 is clamped, the product forming surface 56 comes closer to the copper plate 3 inserted into the copper plate insertion part 51, and the product part 34 is formed. Is done.

  The biscuit portion 31 is a portion provided to prevent solidification and shrinkage of the high-temperature molten metal 39 and generation of a cavity.

  Referring to FIGS. 19 and 20, the runner portion 32 is a portion for guiding the molten metal 39 injected into the biscuit portion 31 toward the product portion 34, and the molten metal 39 injected into the runner portion 32 is solidified. A runner 42 is formed.

  The overflow section 35 exhausts the air in the mold extruded by the molten metal 39 from the product section 34 to lower the filling resistance of the molten metal 39 and to push out the molten metal 39 having a deteriorated flow front out of the product section 34. Part.

  Pure aluminum or an aluminum alloy, which is a raw material of the aluminum body 4, can be press-fitted into the mold 21 as the molten metal 39.

  FIGS. 17 to 23 and the flowcharts shown in FIGS. 24A to 24C show an example of a specific method for manufacturing the composite 1 and the heat sink 2 of the present embodiment having the above-described configuration, by using a high-pressure die casting method as an example. It will be described based on the following.

  First, the copper plate 3 is inserted into the copper plate insertion portion 51 of the movable mold 24 (step S1, FIG. 17). The copper plate 3 is formed by forming a groove 5, a through hole 6, and a non-through hole 7 of the copper plate 3, which is a copper plate surface 8 of the copper plate 3 joined to the aluminum body 4, into a mold in which a movable mold 24 and a fixed mold 23 are combined. It is inserted toward the division surface 25 side. The movable mold 24 is brought closer to the fixed mold 23, and the mold is clamped in combination with the fixed mold 23 (step S2, FIGS. 18 and 19). The casting metal 20 as a raw material of the aluminum body 4 is melted to form a molten metal 39 (step S3). The molten metal 39 is injected from an opening (not shown) of the injection sleeve 26, and the plunger tip (not shown) is advanced to inject the molten metal 39 into the inside of the product part 34 at high speed and high pressure (step S4). . By this step, the molten metal 39 is injected into the grooves 5, the through holes 6, and the non-through holes 7 of the copper plate 3, and the copper plate 3 can be cast with the casting metal 20. Thereafter, the molten metal 39 is solidified by cooling (step S5, FIG. 20). After the molten metal 39 solidifies, the movable mold 24 is separated from the fixed mold 23. At this time, the movable mold 24 is separated from the solid mold 23, and at the same time, the product 44 is extruded by the fixed extrusion 27 of the solid mold 23 and the mold is opened (step S6, FIG. 21). The product 44 is pushed out of the movable mold 24 by the push-out pin 28 of the movable mold 24 (Step 7, FIG. 22). The casting scheme 40 is removed from the product 44 to obtain a die-cast product 46 having a desired shape (FIG. 23).

  As a manufacturing method other than high-pressure die casting, for example, a casting method such as mold gravity casting or mold low-pressure casting can be used. In mold gravity casting or mold low-pressure casting, for example, a copper plate insertion portion 51 for inserting the copper plate 3 into a mold 21 composed of an upper mold and a lower mold is formed, and the copper plate 3 is inserted into the copper plate insertion portion 51. After the insertion, the mold 39 is filled with a molten metal 39 obtained by melting the casting metal 20 as a raw material of the aluminum body 4. In the mold gravity casting, the product 44 is formed by the own weight of the molten metal 39 without applying pressure from the outside, and in the mold low pressure casting, the molten metal 39 is filled into the die at a low pressure and at a low speed to form the product 44, The composite 1 of the copper plate 3 and the aluminum body 4 can be manufactured by casting the copper plate 3 in the aluminum body 4.

  As described above, the composite 1 of the present embodiment includes the copper plate 3 and the aluminum body 4 bonded to the copper plate 3, and the copper plate 3 has a copper plate surface 8, which is a surface to which the aluminum body 4 is bonded, The aluminum body 4 has at least one of the groove 5, the through hole 6, and the non-through hole 7. The aluminum body 4 has a fitting protrusion 9 that fits into the groove 5, the through hole 6, or the non-through hole 7.

  Since the fitting protrusion 9 of the aluminum body 4 is fitted into the groove 5, the through hole 6, and the non-through hole 7 formed in the copper plate 3 and mechanically connected, the number of manufacturing steps and manufacturing cost can be reduced. A highly adhesive bond between the copper plate 3 and the aluminum body 4 can be realized.

  In the composite 1 of the present embodiment, the groove 5 has an inverted tapered shape in which the width decreases toward the copper plate surface 8, and the through holes 6 and the non-through holes 7 are parallel to the copper plate surface 8 toward the copper plate surface 8. It can have an inverted tapered shape with a reduced cross-sectional area.

  In this case, since the through-hole 6 has an inverted tapered shape, the fitting protrusion 9 of the aluminum body 4 fitted into the through-hole 6 is prevented from coming off, and the further distance between the copper plate 3 and the aluminum body 4 is further reduced. High bonding strength and high adhesion can be maintained.

  In the composite 1 of the present embodiment, a reaction layer 13 between the copper of the copper plate 3 and the metal 20 constituting the aluminum body 4 can be provided between the copper plate 3 and the aluminum body 4.

  In this case, the formation of the reaction layer 13 prevents separation between the copper plate 3 and the aluminum body 4 due to thermal stress, and can enhance the adhesion between the two.

  In the composite 1 of the present embodiment, the aluminum body 4 can have a plurality of corrugated fins 11.

  In this case, by making the fins 11 have a corrugated shape, the average flow velocity of the fluid passing between the fins 11 can be improved as compared with the case of the conventional fin shape.

  In the composite 1 of the present embodiment, the composite 1 can be the heat sink 2.

  In this case, the heat generated by the uncooled object (not shown) is transmitted through the plane of the copper plate 3 having high thermal conductivity, and further from the joint surface 10 between the copper plate 3 and the aluminum body 4 having high adhesion. The heat sink 2 having high heat dissipation, which can efficiently radiate heat, can be realized.

  In the present embodiment, the method for manufacturing the composite 1 includes a step of inserting the copper plate 3 having at least one of the groove 5, the through hole 6, and the non-through hole 7 into the mold 21, and an aluminum body to be joined to the copper plate 3. 4. A step of filling the inside of the mold 21 with the molten metal 39 obtained by melting the metal 20 as the raw material of Step 4, and casting the copper plate 3 in the aluminum body 4.

  In this case, the aluminum body 4 has a structure in which the fitting protrusions 9 of the aluminum body 4 are fitted into the grooves 5, the through holes 6, and the non-through holes 7 formed in the copper plate 3 and are mechanically connected. Since this can be realized by casting the copper plate 3 on the metal 20, the number of manufacturing steps and the manufacturing cost can be reduced, and a highly adhesive bond between the copper plate 3 and the aluminum body 4 can be realized.

  In the manufacturing method of the composite 1 of the present embodiment, the groove 5 has an inverted tapered shape in which the width decreases toward the copper plate surface 8 of the copper plate 3 which is the surface to be joined to the aluminum body 4, and the through hole 6 and the non-through hole The hole 7 can have an inverted tapered shape in which a cross-sectional area of a cross section parallel to the copper plate surface 8 decreases toward the copper plate surface 8 of the copper plate 3 which is a surface to be joined to the aluminum body 4.

  In this case, since the through-hole 6 has an inverted tapered shape, the fitting protrusion 9 of the aluminum body 4 fitted into the through-hole 6 is prevented from coming off, and the further distance between the copper plate 3 and the aluminum body 4 is further reduced. High bonding strength and high adhesion can be maintained.

  In the method of manufacturing the composite 1 of the present embodiment, the plating layer 14 may be formed on the copper plate surface 8 which is the surface of the copper plate 3 that is to be joined to the aluminum body 4.

  In this case, the adhesion between the copper plate 3 and the aluminum body 4 can be enhanced by the plating layer 14.

  In the method for manufacturing the composite 1 of the present embodiment, the plating layer 14 can be an electroless nickel plating layer.

  In this case, the adhesion between the copper plate 3 and the aluminum body 4 can be increased while suppressing an increase in the thermal resistance between the copper plate 3 and the aluminum body 4.

  In the method for manufacturing the composite 1 of the present embodiment, the mold 21 can be configured to mold the plurality of corrugated fins 11 on the aluminum body 4.

  In this case, by forming the fins 11 having a corrugated shape, the average flow velocity of the fluid passing between the fins 11 can be improved as compared with the case of the conventional fin shape.

  In the method for manufacturing the composite 1 of the present embodiment, the composite 1 can be used as the heat sink 2.

  In this case, the heat generated by the uncooled material (not shown) is transmitted through the plane of the copper plate 3 having high thermal conductivity, and further from the joint surface 10 between the copper plate 3 and the aluminum body 4 having high adhesion. The heat sink 2 with high heat dissipation, which can transmit heat with high efficiency and can reduce the number of manufacturing steps and manufacturing cost, can be manufactured.

  As described above, the present invention has been described based on the embodiments. However, the present invention can be variously modified. For example, in the present invention, not only the rectangular copper plate 3 and the aluminum body 4 illustrated in the present embodiment but also the shapes of the copper plate 3 and the aluminum body 4 can be variously changed. When the shape of the copper plate 3 is changed, the shape of the copper plate insertion portion 51 may be adjusted to the shape of the changed copper plate 3. By changing the shape of the mold 21, the aluminum body 4 can have any shape as long as it can be manufactured by casting.

DESCRIPTION OF SYMBOLS 1 Composite body 2 Heat sink 3 Copper plate 4 Aluminum body 5 Groove 6 Through hole 7 Non-through hole 8 Copper plate surface 9 Fitting protrusion
10 Joint surface
11 Fins
13 Reaction layer
14 Plating layer
15 Surface of copper plate in contact with uncooled material
16 Taper side
18 Copper sheet surface
19 Surface of mating protrusion
20 Metals (metals for casting)
21 Mold
23 Fixed type
24 Movable type
34 Product Department
39 Melt
44 products
46 Die-cast products
51 Copper plate insertion part

  The present invention relates to a composite manufactured by a casting method utilizing a cast-in and a manufacturing method thereof.

  2. Description of the Related Art Conventionally, a heat sink has been proposed in which an aluminum heat sink including pure aluminum and an aluminum alloy is combined with a copper plate using copper having a thermal conductivity approximately twice that of aluminum. For example, in Patent Literatures 1 and 2, a copper plate is surface-bonded to a base plate of an aluminum heat sink or an aluminum fin by soldering. In Patent Document 3, a composite plate in which an interface between a copper plate and an aluminum plate is metal-bonded is formed, and a radiation fin made of aluminum is provided on the surface of the aluminum plate of the composite plate.

JP-A-2002-237557 JP-A-2002-324880 JP-A-9-298259

In the heat sinks of Patent Literatures 1 and 2, heat generated by the object to be cooled, for example, a semiconductor chip or the like, is transmitted in a plane of a copper plate having a high thermal conductivity, so that heat radiation can be improved. However, since it is necessary to join the copper plate and the aluminum base plate or fin by soldering, the number of manufacturing steps increases and the manufacturing cost also increases. In addition, there is a problem that heat resistance increases due to the presence of the solder, and heat of the object to be cooled cannot be efficiently transmitted from the copper plate to aluminum, so that heat cannot be effectively radiated to the outside.

  Also in the heat sink of Patent Document 3, the fin of the heat sink must be formed after the aluminum plate and the copper plate are joined, and there is a problem that the increase in the number of manufacturing steps and the accompanying increase in the manufacturing cost cannot be solved.

  Conventionally, a technique of casting a copper material with aluminum has been proposed, but due to a problem such as aluminum peeling off from the copper material due to thermal stress during casting, a high adhesion between the copper material and the aluminum is required. It has been difficult to produce a heat sink having the same by casting.

  The present invention has been made in view of such circumstances, and is intended to cast a copper plate having at least one of a groove, a through hole, and a non-through hole with a casting metal that is a raw material of an aluminum body. The present invention provides a composite which can reduce the number of manufacturing steps and manufacturing cost, and can realize high adhesion between a copper plate and an aluminum body, and a method for manufacturing the same.

  In order to solve the problem, the present invention includes a copper plate and an aluminum body joined to the copper plate, wherein the copper plate has grooves, through holes and non-penetrations on a surface of the copper plate to which the aluminum body is joined. A composite having at least one of the holes, wherein the aluminum body has a fitting protrusion that fits into the groove, the through hole, or the non-through hole.

  In the composite, the groove has an inverted tapered shape in which a width decreases toward the copper plate surface, and the through-hole and the non-through hole have a cross-sectional area of a cross section parallel to the copper plate surface toward the copper plate surface. May have an inversely tapered shape in which

  In the composite, a reaction layer of copper of the copper plate and a metal constituting the aluminum body may be provided between the copper plate and the aluminum body.

  In the composite, the aluminum body may have a plurality of corrugated fins.

  In the composite, the composite may be a heat sink.

  The present invention includes a step of inserting a copper plate having at least one of a groove, a through hole and a non-through hole into a mold, and melting a metal as a raw material of an aluminum body to be joined to the copper plate with a molten metal of the mold. Filling the inside and casting the copper plate in the aluminum body. A method for producing a composite of the copper plate and the aluminum body.

  In the method of manufacturing the composite, the groove has an inverted tapered shape in which a width decreases toward a copper plate surface of the copper plate, which is a surface to be joined to the aluminum body, and the through hole and the non-through hole are formed of the aluminum. The copper plate may have a reverse tapered shape in which a cross-sectional area of a cross section parallel to the copper plate surface decreases toward a copper plate surface of the copper plate which is a surface to be joined to a body.

  In the method of manufacturing the composite, a plating layer may be formed on a surface of the copper plate, which is a surface to be joined to the aluminum body of the copper plate.

  In the method of manufacturing the composite, the plating layer may be an electroless nickel plating layer.

  In the method of manufacturing a composite, the mold may be configured to form a plurality of corrugated fins on the aluminum body.

  In the method of manufacturing the composite, the composite may be a heat sink.

  According to the composite of the present invention and the method for producing the same, the number of production steps and the production cost are reduced, the adhesion between the copper plate and the aluminum body is increased, and a composite applicable to, for example, a heat sink having high heat dissipation is realized. it can.

It is a schematic diagram of a side section of a composite concerning an embodiment of the present invention. It is the perspective photograph figure which looked at the composite (heat sink) concerning the embodiment of the present invention from the bottom side (the copper plate side). It is the perspective photograph figure which looked at the composite (heat sink) concerning the embodiment of the present invention from the upper part (the aluminum body side). It is a top view which shows an example of the lattice-shaped groove | channel formed in the surface of the copper plate concerning embodiment of this invention. It is a top view which shows an example of the cross-shaped groove | channel formed in the surface of the copper plate concerning embodiment of this invention. It is EE sectional drawing of FIG.4 and FIG.5 which shows the groove | channel of the reverse taper shape formed in the surface of the copper plate which concerns on embodiment of this invention. It is a photograph of the side section which expands and shows the mode that the fitting projection part of the aluminum body (made of aluminum alloy) fits into the groove of the copper plate concerning the embodiment of the present invention. It is a top view which shows an example of the through-hole and the non-through-hole formed in the surface of the copper plate concerning embodiment of this invention. FIG. 9 is a cross-sectional view taken along the line AA of FIG. 8 illustrating an example of a reverse tapered through hole formed in the surface of the copper plate according to the embodiment of the present invention. It is a photograph figure of the side section of the compound (heat sink) which formed the through-hole in the surface of the copper plate concerning the embodiment of the present invention, and cast the copper plate with the metal (aluminum alloy) for casting. It is a photograph of the side section which expands and shows the mode that the fitting projection part of the aluminum body (made of an aluminum alloy) fits into the through-hole of the copper plate which concerns on embodiment of this invention. FIG. 9 is a cross-sectional view taken along the line AA of FIG. 8 illustrating an example of a non-through hole having an inverted taper shape formed on the surface of the copper plate according to the embodiment of the present invention. It is a photograph figure which expands and shows the side cross section of the joining surface of the copper plate and aluminum body (made of an aluminum alloy) which concern on embodiment of this invention. It is the bottom surface photograph figure which looked at the composite produced by forming a slot in the surface of the copper plate concerning the embodiment of the present invention from the copper plate side. It is a schematic diagram of a side section of a composite having a plating layer according to an embodiment of the present invention. FIG. 2 is a side sectional view showing a mold for producing a composite according to the embodiment of the present invention. It is a side sectional view showing signs that a metallic mold concerning an embodiment of the present invention is opened and a copper plate is inserted in a movable metallic mold. FIG. 4 is a side sectional view showing a state of a mold clamping operation of the mold according to the embodiment of the present invention. It is a sectional side view showing signs that a metallic mold concerning an embodiment of the present invention was made into a mold clamped state. It is a sectional side view showing signs that casting metal is cast into a metallic mold concerning an embodiment of the present invention. It is a sectional side view showing signs that a metallic mold concerning an embodiment of the present invention was made to open a metallic mold after cooling. It is a sectional side view showing signs that a product is extruded from a metallic mold concerning an embodiment of the present invention. FIG. 3 is a side sectional view showing a die-cast product extruded from a mold according to an embodiment of the present invention and separated from a casting plan. It is a flowchart which shows the flow of a procedure from insertion of the copper plate to the movable die to extrusion of the product which concerns on embodiment of this invention.

  Hereinafter, preferred embodiments of a composite according to the present invention and a method for producing the same will be described with reference to the drawings.

  FIG. 1 shows a side sectional view of the composite 1, and FIG. 2 shows a photograph of the composite 1 of the present embodiment. The composite 1 includes a copper plate 3 and an aluminum body 4 joined to the copper plate 3.

The raw material of the copper plate 3 is, for example, pure copper or a copper alloy. The copper plate 3 is, for example, a flat plate made of these raw materials. The raw material of the aluminum body 4 is, for example, pure aluminum or an aluminum alloy. The aluminum body 4 is a metal body manufactured by using these materials and molding by casting. The shape of the aluminum body 4 is not particularly limited, but may be, for example, a flat plate or a heat sink having fins. Aluminum alloys include pure aluminum such as silicon (Si), copper (Cu), magnesium (Mg), and nickel (Ni), such as aluminum-silicon alloys, aluminum-copper-silicon alloys, and aluminum-magnesium alloys. ), Manganese (Mn), zinc (Zn) and other metal elements. By using an aluminum alloy of a high thermal conductive material as a raw material of the aluminum body 4, the heat sink 2 can be attached to a cooled object (not shown) by brazing. The composite 1 of the present embodiment can be manufactured by joining the copper plate 3 and the aluminum body 4 by casting the copper plate 3 in the aluminum body 4.

  In the present embodiment, an application example in which the composite 1 is a heat sink 2 will be described. In FIG. 2, the aluminum body 4 constituting the heat sink 2 has a plurality of fins 11 having a height in the vertical direction from the aluminum body 4, but has a flat shape without the fins 11 as shown in FIG. You can also. The fin 11 may have a corrugated shape as shown in FIG. 3 or a rectangular shape. When the fins 11 have a corrugated shape, the average flow velocity of the fluid passing between the fins 11 can be improved and the cooling efficiency can be increased as compared with the case of a rectangular shape.

  The copper plate 3 has at least one of a groove 5, a through hole 6, and a non-through hole 7 on a copper plate surface 8 to which the aluminum body 4 is bonded. 4 and 5 show examples of forming the groove 5. FIG. In FIG. 4, grooves 5 are formed in a grid pattern on the copper plate surface 8 of the copper plate 3. In FIG. 5, a cross-shaped groove 5 is dug in the copper plate surface 8 of the copper plate 3, and a groove is dug in a diagonal line of the copper plate 3. The groove 5 can be dug by machining. As shown in FIG. 1, the fitting protrusion 9 of the aluminum body 4 is fitted into the groove 5. Thereby, the aluminum body 4 is mechanically connected to the copper plate 3, and high bonding force and high adhesion between the copper plate 3 and the aluminum body 4 can be realized. The same applies to the through hole 6 shown in FIG. 9 and the non-through hole 7 shown in FIG.

  FIG. 6 shows an example of a side sectional view of the groove 5 (a sectional view taken along line EE in FIGS. 4 and 5). The groove 5 has a predetermined depth in the thickness direction of the copper plate 3. The depth of the groove 5 is not particularly limited, and can be made relatively shallow, for example, from the copper plate surface 8 to 1/4 of the thickness of the copper plate 3, or relatively deep, up to 3/4. . For example, in FIG. 6, the groove 5 has a half depth with respect to the thickness direction of the copper plate 3. The width of the groove 5 can be constant in the thickness direction of the copper plate 3. On the other hand, as shown in FIG. 6, the groove 3 may have an inverted taper shape in which the width becomes narrower toward the copper plate surface 8 with the aluminum body 4 (upward in the figure). Since the groove 5 has the reverse tapered shape, the fitting projection 9 of the aluminum body 4 fitted in the groove 5 is prevented from coming off from the groove 5 as shown in FIG. It is possible to realize a further high bonding force and a high adhesion with the body 4. The angle of the reverse taper can be appropriately set, for example, so that the tapered side surface 16 has an angle α with respect to a perpendicular P to the copper plate 3. The angle α is not particularly limited, but is preferably 1 ° to 10 °, more preferably 3 ° to 8 °, and further preferably 4 ° to 6 °.

  FIG. 7 is an enlarged cross-sectional photograph showing a cut surface near the groove 5 of the actually manufactured heat sink 2. In the figure, a groove 5 having a depth of 1 mm is dug into a copper plate 3 having a thickness of 2 mm, and the width of the groove 5 is set to 3 mm at the largest portion. The reverse taper angle α was 5 °. The fitting protrusion 9 of the aluminum plate, which is the aluminum body 4, is fitted into the groove 5 formed in the copper plate 3 without any gap, and there is no gap or peeling off at the joint surface 10 between the copper plate 3 and the aluminum body 4, so that it is in close contact. Can be confirmed to be high.

  In FIG. 8, a through hole 6 penetrating in the thickness direction of the copper plate 3 is formed in the copper plate surface 8 of the copper plate 3. The through holes 6 can be formed by machining. In the figure, a total of twelve through holes 6 are formed, which are regularly arranged in three rows in the vertical direction and four rows in the horizontal direction. The number and the distance between the adjacent through holes 6 are not limited. For example, the through holes 6 may be formed only near the four corners of the copper plate 3, or the through holes 6 may be formed in the center of the copper plate 3. The cross-sectional area of the cross section of the through hole 6 parallel to the copper plate surface 8 can be constant in the thickness direction of the copper plate 3. On the other hand, as shown in the side sectional view of FIG. 9 (sectional view taken along the line AA of FIG. 8), the through hole 6 faces the copper plate surface 8 of the copper plate 3 which is the surface to be joined to the aluminum body 4 (FIG. 9). May have an inverted tapered shape in which the cross-sectional area decreases. Since the through-hole 6 has the reverse tapered shape, the fitting protrusion 9 of the aluminum body 4 fitted in the through-hole 6 is prevented from coming out of the through-hole 6, and the copper plate 3 and the aluminum body 4 Further, high bonding strength and high adhesion can be maintained. The angle β of the reverse taper is not particularly limited, but is preferably 2 ° to 20 °, more preferably 6 ° to 16 °, and further preferably 8 ° to 12 °. The shape of the through hole 6 is not limited to a circle, but may be, for example, a polygon.

FIG. 10 is a photograph of the heat sink 2 actually manufactured. In the figure, the maximum diameter of the through hole 6 is set to 3 mm and the angle β of the reverse taper is set to 10 ° for the copper plate 3 having a thickness of 2 mm. The fitting protrusion 9 of the aluminum body 4 is fitted in the through hole 6 formed in the copper plate 3 . FIG. 11 is a cross-sectional photographic view in which a cut surface showing the vicinity of the through hole 6 is enlarged. The fitting projection 9 of the aluminum body 4 is fitted into the through-hole 6 formed in the copper plate 3 without any gap, and there is no gap or separation between the copper plate 3 and the aluminum body 4, and the adhesion is high. You can check.

As shown in the side sectional view of FIG. 12 (the sectional view taken along the line AA of FIG. 8), the non-through hole 7 can be formed in the copper plate 3 . The non-through hole 7 can be dug by machining. A top view showing an example of the non-through hole 7 is the same as FIG. The non-through hole 7 has a predetermined depth in the thickness direction of the copper plate 3. As in the case of the above-described groove 5, the depth of the non-through-hole 7 can be appropriately set. Similarly to the through-hole 6, the cross-sectional area of the non-through-hole 7 may be constant in the thickness direction of the copper plate 3, or may be toward the copper plate surface 8 of the copper plate 3, which is the surface to be joined to the aluminum body 4 (FIG. 12). May have an inverted tapered shape in which the cross-sectional area decreases. The angle γ of the reverse taper is not particularly limited, but is preferably 2 ° to 20 °, more preferably 6 ° to 16 °, and further preferably 8 ° to 12 °. The arrangement, the number, and the shape of the non-through holes 7 can be appropriately set similarly to the through holes 6.

  FIG. 13 is a cross-sectional photographic view in which a cut surface showing the joint surface 10 between the copper plate 3 and the aluminum body 4 is enlarged. Reference numeral 13 denotes a reaction layer between copper and an aluminum alloy constituting the aluminum body 4. A reaction layer 13 between the copper of the copper plate 3 and the metal 20 constituting the aluminum body 4 is provided between the copper plate 3 and the aluminum body 4. Are formed. By forming the reaction layer 13, the bonding surface 10 between the copper plate 3 and the aluminum body 4 has high bonding and adhesion. Further, from the figure, it can be confirmed that there is no gap or separated portion on the bonding surface 10.

When the groove 5 is formed in the copper plate 3, as shown in FIG. 14, the surface 15 of the copper plate 3 in contact with the object to be cooled (not shown) can be easily made a flat surface. The heat spreads efficiently and is preferable. The same applies to the case of the non-through hole 7. On the other hand, in the case of the through-hole 6, the surface 19 of the fitting projection 9 of the aluminum body 4 is exposed on the surface 18 of the copper plate 3 as shown in FIG. The surface 18 of the copper plate 3 and the surface 19 of the fitting projection 9 can be made flush with each other by adjusting conditions such as pressure and / or devising the shape of the mold.

  Before casting the copper plate 3 in the aluminum body 4, a plating layer 14 may be formed between the copper plate 3 and the aluminum body 4. By forming the plating layer 14, the adhesion between the copper plate 3 and the aluminum body 4 can be further improved. The plating layer 14 may be formed only on the copper plate surface 8 which is the surface to be joined to the aluminum body 4 of the copper plate 3, or may be formed on the entire surface of the copper plate 3. The plating layer 14 may be formed before forming the groove 5, the through hole 6, and the non-through hole 7, or may be formed after forming the groove 5, the through hole 6, and the non-through hole 7. Even if the plating layer 14 is formed, the reaction layer 13 of the copper of the copper plate 3 and the metal 20 constituting the aluminum body 4 may be formed as described above because the thickness of the plating layer 14 is small. The reaction layer 13 may include plating of the plating layer.

  The plating layer 14 may be formed beforehand on the surface of the copper plate 3 and / or the aluminum body 4 before casting the copper plate 3 on the aluminum body 4. There is no need for 14 to remain. As shown in FIG. 15, the plating layer 14 may remain between the joined copper plate 3 and the aluminum body 4 in some cases. The bonding between the copper plate 3 and the aluminum body 4 includes the case where the plating layer 14 remains and the plating layer 14 exists between the copper plate 3 and the aluminum body 4. The plating layer 14 can be, for example, an electroless nickel plating layer.

  In the manufacturing method for manufacturing the composite 1 and the heat sink 2 of the present embodiment, the copper plate 3 having at least one of the groove 5, the through hole 6, and the non-through hole 7 in the aluminum body 4 can be cast. The method is not particularly limited as long as it can be performed. Hereinafter, a manufacturing method using high-pressure die casting will be described as an example.

  FIG. 16 shows a mold 21 for manufacturing the composite 1 and the heat sink 2 of the present embodiment. The mold 21 includes a fixed mold 23 and a movable mold 24 that are combined with each other during casting. The fixed mold 23 and the movable mold 24 can be manufactured using, for example, SKD61 or the like as a material. A cylindrical injection sleeve 26 is connected so as to communicate with the product part 34 in the mold 21.

  Referring to FIG. 16, the mold 21 is opposed to the fixed mold 23, the movable mold 24 combined with the fixed mold 23 during casting, and the fixed mold 23 when the movable mold 24 is combined with the fixed mold 23. On the surface of the movable mold 24, a copper plate insertion portion 51 formed by being dug into a predetermined shape so as to match the shape of the copper plate 3, and a runner portion 32 formed by being dug by the movable mold 24 so as to extend from the biscuit portion 31. And a gate unit 33. The copper plate insertion part 51 may be formed on the fixed die 23.

  17 to 23 are side sectional views showing a state from insertion of the copper plate 3 into the movable mold 24 to extrusion of the product 44.

  As shown in the side sectional views of FIGS. 17 to 19, the movable mold 24 is freely movable between a mold clamping position combined with the fixed mold 23 and a mold open position separated from the fixed mold 23. The movable mold 24 is movable leftward in the figure so as to be separated from the fixed mold 23, and is movable rightward so as to approach. The grooves 5 and the through holes 6 are shown on the copper plate 3 of FIGS. 17 to 23 for convenience.

  As shown in FIGS. 20 to 22, the casting scheme 40 includes a biscuit 41 connected to a product 44, a runner 42, a gate 43, and an overflow 45. Here, the biscuit 41, the runner 42, the gate 43, the product 44, and the overflow 45 respectively correspond to the biscuit part 31, the runner part 32, the gate part 33, the product part 34, and the overflow part 35 formed in the mold 21 shown in FIG. And the molten metal 39 solidified. The casting plan 40 is necessary only at the time of casting, and is an unnecessary part for the final product. Therefore, the casting method 40 is separated from the product 44 to complete the die-cast product 46 shown in FIG. In the present embodiment, the product connected to the casting plan 40 is referred to as a product 44, and the product obtained by separating the casting plan 40 is referred to as a die-cast product 46. In this embodiment, the die-cast product 46 becomes the composite 1 such as the heat sink 2.

  The fixed mold 23 is provided with an injection sleeve 26 and a plunger tip (not shown) slidable in the injection sleeve 26, and a molten metal 39 is injected into the injection sleeve 26 from an opening (not shown). Configured as possible.

  The product part 34 is an internal space in which the product 44 is cast, and has a dug surface (not shown) corresponding to a desired product shape such as the heat sink 2 having the corrugated fins 11.

  The fixed die 23 has a product forming surface 56 that forms an internal space (cavity) 52 as a product part 34 that is a space filled with the molten metal 39 when the molten metal 39 is injected in combination with the movable die 24. When the product forming surface 56 of the fixed mold 23 and the movable mold 24 approach each other, the product part 34 inside the mold 21 is formed. The copper plate 3 is inserted into the copper plate insertion portion 51 of the movable mold 24. When the movable mold 24 moves closer to the fixed mold 23 when the mold 21 is clamped, the product forming surface 56 comes closer to the copper plate 3 inserted into the copper plate insertion part 51, and the product part 34 is formed. Is done.

  The biscuit portion 31 is a portion provided to prevent solidification and shrinkage of the high-temperature molten metal 39 and generation of a cavity.

  Referring to FIGS. 19 and 20, the runner portion 32 is a portion for guiding the molten metal 39 injected into the biscuit portion 31 toward the product portion 34, and the molten metal 39 injected into the runner portion 32 is solidified. A runner 42 is formed.

  The overflow section 35 exhausts the air in the mold extruded by the molten metal 39 from the product section 34 to lower the filling resistance of the molten metal 39 and to push out the molten metal 39 having a deteriorated flow front out of the product section 34. Part.

  Pure aluminum or an aluminum alloy, which is a raw material of the aluminum body 4, can be press-fitted into the mold 21 as the molten metal 39.

  FIGS. 17 to 23 and the flowcharts shown in FIGS. 24A to 24C show an example of a specific method for manufacturing the composite 1 and the heat sink 2 of the present embodiment having the above-described configuration, by using a high-pressure die casting method as an example. It will be described based on the following.

  First, the copper plate 3 is inserted into the copper plate insertion portion 51 of the movable mold 24 (step S1, FIG. 17). The copper plate 3 is formed by forming a groove 5, a through hole 6, and a non-through hole 7 of the copper plate 3, which is a copper plate surface 8 of the copper plate 3 joined to the aluminum body 4, into a mold in which a movable mold 24 and a fixed mold 23 are combined. It is inserted toward the division surface 25 side. The movable mold 24 is brought closer to the fixed mold 23, and the mold is clamped in combination with the fixed mold 23 (step S2, FIGS. 18 and 19). The casting metal 20 as a raw material of the aluminum body 4 is melted to form a molten metal 39 (step S3). The molten metal 39 is injected from an opening (not shown) of the injection sleeve 26, and the plunger tip (not shown) is advanced to inject the molten metal 39 into the inside of the product part 34 at high speed and high pressure (step S4). . By this step, the molten metal 39 is injected into the grooves 5, the through holes 6, and the non-through holes 7 of the copper plate 3, and the copper plate 3 can be cast with the casting metal 20. Thereafter, the molten metal 39 is solidified by cooling (step S5, FIG. 20). After the molten metal 39 solidifies, the movable mold 24 is separated from the fixed mold 23. At this time, the movable mold 24 is separated from the solid mold 23, and at the same time, the product 44 is extruded by the fixed extrusion 27 of the solid mold 23 and the mold is opened (step S6, FIG. 21). The product 44 is pushed out of the movable mold 24 by the push-out pin 28 of the movable mold 24 (Step 7, FIG. 22). The casting scheme 40 is removed from the product 44 to obtain a die-cast product 46 having a desired shape (FIG. 23).

  As a manufacturing method other than high-pressure die casting, for example, a casting method such as mold gravity casting or mold low-pressure casting can be used. In mold gravity casting or mold low-pressure casting, for example, a copper plate insertion portion 51 for inserting the copper plate 3 into a mold 21 composed of an upper mold and a lower mold is formed, and the copper plate 3 is inserted into the copper plate insertion portion 51. After the insertion, the mold 39 is filled with a molten metal 39 obtained by melting the casting metal 20 as a raw material of the aluminum body 4. In the mold gravity casting, the product 44 is formed by the own weight of the molten metal 39 without applying pressure from the outside, and in the mold low pressure casting, the molten metal 39 is filled into the die at a low pressure and at a low speed to form the product 44, The composite 1 of the copper plate 3 and the aluminum body 4 can be manufactured by casting the copper plate 3 in the aluminum body 4.

  As described above, the composite 1 of the present embodiment includes the copper plate 3 and the aluminum body 4 bonded to the copper plate 3, and the copper plate 3 has a copper plate surface 8, which is a surface to which the aluminum body 4 is bonded, The aluminum body 4 has at least one of the groove 5, the through hole 6, and the non-through hole 7. The aluminum body 4 has a fitting protrusion 9 that fits into the groove 5, the through hole 6, or the non-through hole 7.

  Since the fitting protrusion 9 of the aluminum body 4 is fitted into the groove 5, the through hole 6, and the non-through hole 7 formed in the copper plate 3 and mechanically connected, the number of manufacturing steps and manufacturing cost can be reduced. A highly adhesive bond between the copper plate 3 and the aluminum body 4 can be realized.

  In the composite 1 of the present embodiment, the groove 5 has an inverted tapered shape in which the width decreases toward the copper plate surface 8, and the through holes 6 and the non-through holes 7 are parallel to the copper plate surface 8 toward the copper plate surface 8. It can have an inverted tapered shape with a reduced cross-sectional area.

  In this case, since the through-hole 6 has an inverted tapered shape, the fitting protrusion 9 of the aluminum body 4 fitted into the through-hole 6 is prevented from coming off, and the further distance between the copper plate 3 and the aluminum body 4 is further reduced. High bonding strength and high adhesion can be maintained.

  In the composite 1 of the present embodiment, a reaction layer 13 between the copper of the copper plate 3 and the metal 20 constituting the aluminum body 4 can be provided between the copper plate 3 and the aluminum body 4.

  In this case, the formation of the reaction layer 13 prevents separation between the copper plate 3 and the aluminum body 4 due to thermal stress, and can enhance the adhesion between the two.

  In the composite 1 of the present embodiment, the aluminum body 4 can have a plurality of corrugated fins 11.

  In this case, by making the fins 11 have a corrugated shape, the average flow velocity of the fluid passing between the fins 11 can be improved as compared with the case of the conventional fin shape.

  In the composite 1 of the present embodiment, the composite 1 can be the heat sink 2.

In this case, the heat generated by the object to be cooled (not shown) is transmitted through the plane of the copper plate 3 having high thermal conductivity, and further from the joint surface 10 between the copper plate 3 and the aluminum body 4 having high adhesion. The heat sink 2 having high heat dissipation, which can efficiently radiate heat, can be realized.

  In the present embodiment, the method for manufacturing the composite 1 includes a step of inserting the copper plate 3 having at least one of the groove 5, the through hole 6, and the non-through hole 7 into the mold 21, and an aluminum body to be joined to the copper plate 3. 4. A step of filling the inside of the mold 21 with the molten metal 39 obtained by melting the metal 20 as the raw material of Step 4, and casting the copper plate 3 in the aluminum body 4.

  In this case, the aluminum body 4 has a structure in which the fitting protrusions 9 of the aluminum body 4 are fitted into the grooves 5, the through holes 6, and the non-through holes 7 formed in the copper plate 3 and are mechanically connected. Since this can be realized by casting the copper plate 3 on the metal 20, the number of manufacturing steps and the manufacturing cost can be reduced, and a highly adhesive bond between the copper plate 3 and the aluminum body 4 can be realized.

  In the manufacturing method of the composite 1 of the present embodiment, the groove 5 has an inverted tapered shape in which the width decreases toward the copper plate surface 8 of the copper plate 3 which is the surface to be joined to the aluminum body 4, and the through hole 6 and the non-through hole The hole 7 can have an inverted tapered shape in which a cross-sectional area of a cross section parallel to the copper plate surface 8 decreases toward the copper plate surface 8 of the copper plate 3 which is a surface to be joined to the aluminum body 4.

  In this case, since the through-hole 6 has an inverted tapered shape, the fitting protrusion 9 of the aluminum body 4 fitted into the through-hole 6 is prevented from coming off, and the further distance between the copper plate 3 and the aluminum body 4 is further reduced. High bonding strength and high adhesion can be maintained.

  In the method of manufacturing the composite 1 of the present embodiment, the plating layer 14 may be formed on the copper plate surface 8 which is the surface of the copper plate 3 that is to be joined to the aluminum body 4.

  In this case, the adhesion between the copper plate 3 and the aluminum body 4 can be enhanced by the plating layer 14.

  In the method for manufacturing the composite 1 of the present embodiment, the plating layer 14 can be an electroless nickel plating layer.

  In this case, the adhesion between the copper plate 3 and the aluminum body 4 can be increased while suppressing an increase in the thermal resistance between the copper plate 3 and the aluminum body 4.

  In the method for manufacturing the composite 1 of the present embodiment, the mold 21 can be configured to mold the plurality of corrugated fins 11 on the aluminum body 4.

  In this case, by forming the fins 11 having a corrugated shape, the average flow velocity of the fluid passing between the fins 11 can be improved as compared with the case of the conventional fin shape.

  In the method for manufacturing the composite 1 of the present embodiment, the composite 1 can be used as the heat sink 2.

In this case, the heat generated by the object to be cooled (not shown) is transmitted through the plane of the copper plate 3 having high thermal conductivity, and further from the joint surface 10 between the copper plate 3 and the aluminum body 4 having high adhesion. The heat sink 2 with high heat dissipation, which can transmit heat with high efficiency and can reduce the number of manufacturing steps and manufacturing cost, can be manufactured.

  As described above, the present invention has been described based on the embodiments. However, the present invention can be variously modified. For example, in the present invention, not only the rectangular copper plate 3 and the aluminum body 4 illustrated in the present embodiment but also the shapes of the copper plate 3 and the aluminum body 4 can be variously changed. When the shape of the copper plate 3 is changed, the shape of the copper plate insertion portion 51 may be adjusted to the shape of the changed copper plate 3. By changing the shape of the mold 21, the aluminum body 4 can have any shape as long as it can be manufactured by casting.

DESCRIPTION OF SYMBOLS 1 Composite body 2 Heat sink 3 Copper plate 4 Aluminum body 5 Groove 6 Through hole 7 Non-through hole 8 Copper plate surface 9 Fitting protrusion
10 Joint surface
11 Fins
13 Reaction layer
14 Plating layer
15 Surface of copper plate in contact with object to be cooled
16 Taper side
18 Copper sheet surface
19 Surface of mating protrusion
20 Metals (metals for casting)
21 Mold
23 Fixed type
24 Movable type
34 Product Department
39 Melt
44 products
46 Die-cast products
51 Copper plate insertion part

Claims (11)

Copper plate,
Comprising an aluminum body joined to the copper plate,
The copper plate has at least one of a groove, a through hole, and a non-through hole on a surface of the copper plate that is a surface to which the aluminum body is joined,
The said aluminum body is a composite which has a fitting protrusion which fits in the said groove | channel, the said through-hole, or the said non-through-hole.   The groove has an inverse taper shape in which the width decreases toward the copper plate surface, and the through hole and the non-through hole have an inverse taper in which a cross-sectional area of a cross section parallel to the copper plate surface decreases toward the copper plate surface. The composite of claim 1 having a shape.   3. The composite according to claim 1, further comprising a reaction layer between copper of the copper plate and a metal constituting the aluminum body, between the copper plate and the aluminum body. 4.   The composite according to any one of claims 1 to 3, wherein the aluminum body has a plurality of corrugated fins.   The composite according to any one of claims 1 to 4, wherein the composite is a heat sink. Inserting a copper plate having at least one of a groove, a through hole and a non-through hole into a mold;
Filling the inside of the mold with a molten metal obtained by melting a metal that is a raw material of an aluminum body to be joined to the copper plate, and casting the copper plate in the aluminum body; and a composite of the copper plate and the aluminum body. Manufacturing method.   The groove has an inverted tapered shape in which a width decreases toward a copper plate surface of the copper plate that is a surface to be joined to the aluminum body, and the through hole and the non-through hole are surfaces to be joined to the aluminum body. The method for producing a composite according to claim 6, wherein the copper plate has an inverted tapered shape in which a cross-sectional area of a cross section parallel to the copper plate surface decreases toward the copper plate surface.   The method for producing a composite according to claim 6, wherein a plating layer is formed on a surface of the copper plate, which is a surface to be joined to the aluminum body of the copper plate.   The method for producing a composite according to claim 9, wherein the plating layer is an electroless nickel plating layer.   The method for manufacturing a composite according to claim 6, wherein the mold is configured to form a plurality of corrugated fins on the aluminum body.   The method for producing a composite according to any one of claims 6 to 10, wherein the composite is a heat sink.