TWI651193B - 金屬陶瓷積層散熱基板之製造方法、及包含該金屬陶瓷積層散熱基板之電子裝置及發光二極體 - Google Patents
金屬陶瓷積層散熱基板之製造方法、及包含該金屬陶瓷積層散熱基板之電子裝置及發光二極體 Download PDFInfo
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- TWI651193B TWI651193B TW106142809A TW106142809A TWI651193B TW I651193 B TWI651193 B TW I651193B TW 106142809 A TW106142809 A TW 106142809A TW 106142809 A TW106142809 A TW 106142809A TW I651193 B TWI651193 B TW I651193B
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- Prior art keywords
- metal
- manufacturing
- ceramic
- sintered
- hardened
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/64—Heat extraction or cooling elements
- H01L33/642—Heat extraction or cooling elements characterized by the shape
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/12—Apparatus or processes for treating or working the shaped or preshaped articles for removing parts of the articles by cutting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/243—Setting, e.g. drying, dehydrating or firing ceramic articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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Abstract
本發明提供一種金屬陶瓷積層散熱基板之製造方法,其包含有提供一金屬基層;於該金屬基層表面形成一尚未燒結硬化之陶瓷層;及於該尚未燒結硬化之陶瓷層上表面形成金屬線路後進行燒結。本發明之金屬陶瓷積層散熱基板之製造方法可製備出陶瓷層及金屬線路結合強度強的散熱基板,且具有減少製程程序及原料成本之優勢。
Description
本發明係關於一種金屬陶瓷積層散熱基板之製造方法,特別係一種用於發光二極體之金屬陶瓷積層散熱基板之製造方法。
為提供良好散熱效率,散熱基板已由使用塑膠為主體的金屬基印刷電路板(MCPCB)發展為使用陶瓷為主體的散熱基板。目前,常見的陶瓷散熱基板包含低溫共燒結陶瓷(Low-Temperature Co-fired Ceramic,LTCC)、高溫共燒結陶瓷(High-Temperature Co-fired Ceramic,HTCC)、直接覆銅基板(Direct Plate Copper,DPC)及直接接合銅基板(Direct Bonded Copper,DPC)。
目前,用於發光二極體最為普遍的陶瓷散熱基板為低溫共燒結陶瓷(LTCC)所製備,其可改善高溫共燒結陶瓷(HTCC)於製程上需高溫環境而增加製程成本之問題,但低溫共燒結陶瓷(LTCC)及高溫共燒結陶瓷(HTCC)仍為厚膜製程,所獲得散熱基板
存有表面平整度不佳及金屬線路不夠精細的問題。
近年,逐漸又發展出使用直接覆銅基板(DPC)及直接接合銅基板(DPC)之陶瓷散熱基板的製造方法,以製備尺寸小及功率高的發光二極體散熱基板。直接覆銅基板(DPC)雖為薄膜製造法,但需要高溫操作環境才可使金屬層及陶瓷附著性佳,因此製程上仍須成本高的高溫環境。而直接接合銅基板(DPC)則採用真空濺鍍的方法,以獲得金屬層及陶瓷層結合性佳的散熱基板,其表面平整度及金屬線路的精細度也較前三者為佳。
然而,本發明者考量雖然直接接合銅基板(DPC)可改善需高溫共燒結陶瓷(HTCC)、低溫共燒結陶瓷(LTCC)及直接接合銅基板(DPC)需要高溫操作而增加製造成本的問題,但直接接合銅基板(DPC)的真空濺鍍設備較為昂貴,仍有增加陶瓷散熱基板製造成本之慮。另外,陶瓷作為基板常存有表面平整度不佳及金屬線路不夠精細,且陶瓷基板容易碎裂無法做到超薄型及進行外形結構沖壓變形等加工程序。
據此,本發明者之發明目的欲提供一種金屬陶瓷積層散熱基板之製造方法,其可改善習知陶瓷散熱基板之高成本原料及製程及金屬線路與陶瓷結合性強度不佳的問題,並提供具有薄型及可撓性的散熱基板,有效作為電子產品及電子裝置的散熱基板,特別係發光二極體的散熱基板。
即,為達到上述之發明目的,本發明提供一種金屬
陶瓷積層散熱基板之製造方法,其包含有提供一金屬基層;於該金屬基層表面形成一尚未燒結硬化之陶瓷層;及於該尚未燒結硬化之陶瓷層上表面形成金屬線路後進行燒結。
進一步地,於該金屬基層表面形成該尚未燒結硬化之陶瓷層的步驟前,該金屬基層會進行打孔,形成複數個具有金屬內圍的貫孔;於該金屬基層表面形成該尚未燒結硬化之陶瓷層的步驟時,該複數個具有金屬內圍的貫孔會填滿該尚未燒結硬化之陶瓷層;以及,於該燒結之步驟後,進行打孔,形成複數個具有燒結硬化之陶瓷層內圍的貫孔。
進一步地,於該金屬基層表面形成該尚未燒結硬化之陶瓷層的方法係將陶瓷漿塗佈於該金屬基層。
進一步地,該陶瓷漿黏度為500至5000cps。
進一步地,該陶瓷漿塗佈於該金屬基層後,可經預烤形成半固態之陶瓷漿膜為該尚未燒結硬化之陶瓷層。
進一步地,該半固態之陶瓷漿膜為5000至25000cps。
進一步地,該金屬線路之表面形成的方法包含噴墨印刷法、網印印刷法、平版印刷法、雷射金屬沉積3D列印或電子束3D列印。
進一步地,該金屬線路之表面形成的方法包含雷射金屬沉積3D列印或電子束3D列印。
進一步地,該金屬基層可為選自任一項或二種以上由鋁、鋁合金、銅及銅合金所組成之群組。
本發明另提供一種電子裝置,其包含由上所述之製造方法所獲得之金屬陶瓷積層散熱基板。
本發明另提供一種發光二極體,其包含由上所述之製造方法所獲得之金屬陶瓷積層散熱基板。
是以,本發明比起習知技術具有以下優異效果:
1.本發明之金屬陶瓷積層散熱基板之製造方法,係使用金屬基層作為散熱基板的主體,而陶瓷層塗布於該金屬基層之表面上,即為一種金屬陶瓷複合材料,比起習知使用陶瓷基板作為散熱基板的主體,具有平整表面可使金屬線路更為精細,不同於陶瓷基板容易碎裂而無法加工之問題,以金屬基層為主體之金屬陶瓷積層基板具有薄型及可撓性結構,能夠進行外形結構的加工(如沖壓變形),且減少使用高成本陶瓷材料之原料成本。
2.本發明之金屬陶瓷積層散熱基板之製造方法,係於金屬基板上表面形成尚未燒結硬化之陶瓷層後,直接於該尚未燒結硬化之陶瓷層表面形成金屬線路並進行燒結,即製程簡約快速,利於產業利用。。
3.本發明之金屬陶瓷積層散熱基板之製造方法,係於金屬基板上表面形成陶瓷層後,直接於該陶瓷層表面形成金屬線路並進行燒結,即,金屬線路及陶瓷層為同時燒結所完成,因此具有金屬線路及陶瓷層之間的結合強度強之優勢,金屬線路不易剝落。
1‧‧‧金屬基層
3‧‧‧尚未燒結硬化之陶瓷層
3’‧‧‧燒結硬化之陶瓷層
5‧‧‧金屬線路
7‧‧‧具有金屬基層內圍的貫孔
9‧‧‧具有陶瓷層內圍的貫孔
圖1為本發明之金屬陶瓷積層散熱基板之製造方法第一實施態樣的剖面流程示意圖。
圖2為本發明之金屬陶瓷積層散熱基板之製造方法第一實施態樣所獲得之金屬陶瓷積層散熱基板的剖面示意圖。
圖3為本發明之金屬陶瓷積層散熱基板之製造方法第二實施態樣的剖面流程示意圖。
圖4為本發明之金屬陶瓷積層散熱基板之製造方法第二實施態樣所獲得之金屬陶瓷積層散熱基板的剖面示意圖。
有關本發明之詳細說明及技術內容,現就配合圖式說明如下。再者,本發明中之圖式,為說明方便,其比例未必照實際比例繪製,該等圖式及其比例並非用以限制本發明之範圍,在此先行敘明。
本發明所稱之「包含或包括」意指不排除一或多個其他組件、步驟、操作和/或元素的存在或添加至所述之組件、步驟、操作和/或元素。「一」意指該物的語法對象為一或一個以上(即,至少為一)。
本發明之金屬陶瓷積層散熱基板之製造方法,其包含有提供一金屬基層;於該金屬基層表面形成一尚未燒結硬化之陶瓷層;及於該尚未燒結硬化之陶瓷層上表面形成金屬線路後進行燒結。其中,該金屬基層的表面並不限於該金屬基層的單面或雙面,該陶瓷層可為完全分布於該金屬基層全部的外表面;同理。
該金屬線路形成於該陶瓷層上時並不限於該金屬基層上單面或雙面的陶瓷層,該金屬線路可全面分布於該陶瓷層表面。
進一步地,本發明之金屬陶瓷積層散熱基板之製造方法中,於該金屬基層表面形成該尚未燒結硬化之陶瓷層的步驟前,該金屬基層會進行打孔,形成複數個具有金屬內圍的貫孔;於該金屬基層表面形成該尚未燒結硬化之陶瓷層的步驟時,該複數個具有金屬內圍的貫孔會填滿該尚未燒結硬化之陶瓷層;以及,於該燒結之步驟後,進行打孔,形成複數個具有燒結硬化之陶瓷層內圍的貫孔
本發明所述的「金屬基層」可為銅、鋁、銅合金或鋁合金,例如該銅合金包含銅鋅合金、銅錫合金、銅鋁合金、銅矽合金或銅鎳合金,且不限於此等;該鋁合金包含鋁矽合金、鋁鎂矽合金、鋁銅合金、鋁鎂合金、鋁錳合金、鋁鋅合金或鋁鋰合金,且不限於此等;其中,以鋁、鋁合金、銅或銅合金為較佳;該金屬基層之金屬可為前述任一種或二種以上所組合之金屬。
本發明之製造方法中,該金屬基層表面形成該尚未燒結硬化之陶瓷層的方法係將陶瓷漿塗佈於該金屬基層表面;其中,塗佈方法包含刮塗、噴塗、印刷塗佈或輥塗,本發明不限於此等,在此予以說明。更進一步地,該陶瓷漿可經預烤形成半固態之陶瓷漿膜,作為該尚未燒結硬化之陶瓷層。
本發明所述的陶瓷漿在塗佈於該金屬基層之後,會呈現黏稠狀態。該陶瓷漿的組成分包含陶瓷粉、溶劑、分散劑、
黏合劑及增速劑等。其中,該陶瓷粉主要包含硼矽酸系玻璃粉末及各種金屬氧化物、碳化物、氮化物、硼化物、矽化物或其等之組合粉末,例如碳化矽(SiC)、氮化矽(Si3N4)、氮化鋁(AIN)、氧化鋁(Al2O3)、碳化鈦(TiC)、硼化鈦(TiB2)、碳化硼(B4C)、鋯酸鈦酸鉛及鐵酸錳等,本發明不限於此等,且可為任一種或二種以上之組合使用。該溶劑及分散劑包含水、脂肪族烴溶劑、脂環式烴溶劑、芳香族烴溶劑、酮系溶劑、醇系溶劑、醚系溶劑等,具體例包含己烷、癸烷、十二烷、十四烷、環己烷、甲苯、二甲苯、丙酮、甲基乙基酮、甲基異丁基酮、乙酸甲酯、乙酸乙酯、乙酸丙酯、乙酸丁酯、乙酸異丁酯、丙二醇甲醚乙酸酯、甲醇、乙醇、正丙醇、異丙醇、正丁醇、乙二醇、二乙二醇、三乙二醇、丙二醇、甘油、四氫呋喃、乙二醇單甲醚、乙二醇單乙醚、乙二醇單丁醚、1-甲氧基-2-丙醇,本發明不限於此等,且可為任一種或二種以上之組合使用。該黏合劑之具體例如乙烯醇、陽離子化澱粉、甲基纖維素、乙基纖維素、聚乙烯醇縮丁醛、(甲基)丙烯醯胺聚合物、(甲基)丙烯酸聚合物、(甲基)丙烯酸烷基酯聚合物、(甲基)丙烯酸與(甲基)丙烯酸烷基酯之共聚物,本發明不限於此等,且可為任一種或二種以上之組合使用。該增塑劑包含鄰苯二甲酸二丁酯、酸鹽、磷酸鹽、醇迷類、單甘油酸酯、礦物油、多元酯、松香衍生物、沙巴鹽類、檸檬酸鹽類、聚乙二醇、酞酸二辛酯、脂肪酸、多元醇、脂肪酸脂、檸檬酸脂、聚酯增塑劑或環氧增塑劑,本發明不限於此等,且可為任一種或二種以上之組合使用。
本發明所述的「陶瓷漿」黏度為200cps至7000cps,其中以500cps至5,000cps為較佳,例如500cps、600cps、700cps、800cps、900cps、1,000cps、1,300cps、1,500cps、1,800cps、2,000cps、2,300cps、2,500cps、2,800cps、3,000cps、3,300cps、3,500cps、3,800cps、4,000cps、4,300cps、4,500cps、4,800cps或5,000cps。
本發明所述的「半固態之陶瓷漿膜」係使用本發明之陶瓷漿先預烤成半固態裝之陶瓷漿膜,其組成分同上述之陶瓷漿;該半固態裝之陶瓷漿膜黏度範圍為4,000cps至28,000cps,其中以5,000cps至25,000cps為較佳,例如5,000cps、8,000cps、10,000cps、13,000cps、15,000cps、18,000cps、20,000cps或25,000cps。
本發明之製造方法中,該尚未燒結硬化之陶瓷層上表面形成該金屬線路的方法可為習知的印刷電路方法,例如噴墨印刷法、網印印刷法及平版印刷法,或是積層製造之3D列印,例如雷射金屬沉積3D列印及電子束3D列印,將製備金屬線路的金屬粉末印製於該陶瓷層表面,但本發明不限於此等,並以雷射金屬沉積3D列印及電子束3D列印為較佳;其中,該金屬粉末包含金屬、合金或複合金屬等,例如銀、銅、金、鋁、鈉、鉬、鎢、鋅、鎳、鐵、鉑、錫、鉛、銀銅、鎘銅、鉻銅、鈹銅、鋯銅、鋁鎂矽、鋁鎂、鋁鎂鐵、鋁鋯、鐵鉻鋁合金等一種或二種以上所混合的金屬粉末,且不限於此等,其中金屬粉末以鋁、金、銀及銅為較佳。
本發明之製造方法中,該燒結之溫度為200至2000
℃,其中以250至1400℃為較佳;燒結之時間約10至40分鐘,其中以20至30分鐘為較佳。
本發明燒結硬化後之陶瓷層的厚度為10μm至900μm,且以20μm至200μm為較佳,30μm至50μm為更佳,例如30μm、35μm、40μm、45μm或50μm,燒結硬化後之陶瓷層介於此厚度,較不易碎裂且具有可撓性,能承受加工時基板沖壓的力量。
本發明燒結硬化後之陶瓷層上的金屬線路厚度為0.5至40μm,例如0.5μm、1μm、5μm、10μm、15μm、20μm、25μm、30μm、35μm或40μm;線徑寬度為0.5μm以上,且金屬線路亦可為全面分布於該燒結硬化之陶瓷層之上。
本發明之金屬陶瓷積層散熱基板之製造方法所獲得的金屬陶瓷積層散熱基板可作為各種電子裝置的散熱基板,例如發光二極體、電腦、智慧型手機、平板電腦或音響等各類電子裝置,且以發光二極體為較佳。
在下文中,將利用具體實施例特別描寫本發明所揭示之內容。然而,本發明所揭示之內容不限制於下列範例。
請參閱圖1及2,係本發明之金屬陶瓷積層散熱基板之製造方法第一實施態樣以及所獲得之金屬陶瓷積層散熱基板(一)。
本態樣之金屬陶瓷積層散熱基板之製造方法中,其包含有提供一金屬基層1;使用熱噴塗法將陶瓷漿於該金屬基層1的表面,形成一尚未燒結硬化之陶瓷層3,該尚未燒結硬化之陶瓷
層3為為黏稠狀態,黏度為600cps;隨後,使用雷射金屬沉積3D列印於該尚未燒結硬化之陶瓷層3上表面沉積金屬粉末,以印製金屬線路5後於1000℃下進行25分鐘燒結,使該尚未燒結硬化之陶瓷層3燒結為燒結硬化之陶瓷層3’,且該金屬線路5可係完整附著於該燒結硬化之陶瓷層3’,不易剝落,金屬線路之厚度為1μm,線徑寬度為1μm,即獲得本實施態樣之金屬陶瓷積層散熱基板,如圖2所示。
本實施態樣之金屬陶瓷積層散熱基板200可進一步加工製備成發光二極體的散熱基板,例如經由使用黏著劑設置擋牆或使用沖壓方法設置擋牆,形成杯體結構,以放置發光二極體之晶片作為發光二極體的料帶結構。
請參閱圖3及4,係本發明之金屬陶瓷積層散熱基板之製造方法第二實施態樣以及所獲得之金屬陶瓷積層散熱基板(二)。
本態樣之金屬陶瓷積層散熱基板之製造方法中,其包含有提供一金屬基層1;將金屬基層1進行打孔,形成複數個具有金屬內圍的貫孔7;使用熱噴塗法將陶瓷漿於該金屬基層1的表面形成一尚未燒結硬化之陶瓷層3,該尚未燒結硬化之陶瓷層3為黏稠狀態,黏度為600cps,在此同時,該複數個金屬內圍貫孔7會填滿有該尚未燒結硬化之陶瓷層3;隨後,使用雷射金屬沉積3D列印於該陶瓷層3’上表面沉積金屬粉末,以印製金屬線路5後,使該尚未燒結硬化之陶瓷層3燒結為硬化固態的陶瓷層3’,於溫度為
1000℃下進行25分鐘燒結,該金屬線路5可係完整附著於該燒結硬化之陶瓷層3’,不易剝落,金屬線路的厚度為1μm及線徑寬度1μm;在進行打孔,形成複數個具有陶瓷層內圍的貫孔9,即獲得本實施態樣之金屬陶瓷積層散熱基板,如圖4所示。
本實施態樣之金屬陶瓷積層散熱基板400可直接設置發光二極體晶片作為散熱基板使用;此外,亦可進一步加工製備成發光二極體的散熱基板,例如經由使用黏著劑設置擋牆或使用沖壓方法設置擋牆,形成杯體結構,以作為發光二極體的料帶結構。
綜上所述,本發明之金屬陶瓷積層散熱基板之製造方法,係使用金屬基層作為散熱基板的主體,而陶瓷層塗布於該金屬基層之表面上,係為一種金屬陶瓷複合材料,比起習知使用陶瓷基板作為散熱基板的主體,具有平整表面可使金屬線路表面形成時能精細化,且不同於陶瓷基板容易碎裂無法加工之問題,以金屬基層為主體之金屬陶瓷基板具有薄型及可撓性結構,能夠進行外形結構的加工(如沖壓變形),且減少原料成本之優勢。其次,本發明之金屬陶瓷積層散熱基板之製造方法,係於金屬基板上表面形成尚未燒結硬化之陶瓷層後,直接於該尚未燒結硬化之陶瓷層表面形成金屬線路並進行燒結,即製程簡約快速,利於產業利用。此外,本發明之金屬陶瓷積層散熱基板之製造方法,係於金屬基板上表面形成陶瓷層後,直接於該陶瓷層表面形成金屬線路並進行燒結,即,金屬線路及陶瓷層為同時燒結所完成,因
此具有金屬線路及陶瓷層之間的結合強度強之優勢,金屬線路不易剝落。
Claims (11)
- 一種金屬陶瓷積層散熱基板之製造方法,其包含有:提供一金屬基層;於該金屬基層表面形成一尚未燒結硬化之陶瓷層;及於該尚未燒結硬化之陶瓷層上表面形成金屬線路後進行燒結。
- 如請求項1所述之製造方法,更進一步地,於該金屬基層表面形成該尚未燒結硬化之陶瓷層前,該金屬基層會進行打孔,形成複數個具有金屬內圍的貫孔;於該金屬基層表面形成該尚未燒結硬化之陶瓷層的步驟時,該複數個具有金屬內圍的貫孔會填滿該尚未燒結硬化之陶瓷層;以及,於該燒結之步驟後,進行打孔,形成複數個具有燒結硬化之陶瓷層內圍的貫孔。
- 如請求項1或2所述之製造方法,其中,於該金屬基層表面形成該尚未燒結硬化之陶瓷層的方法係將陶瓷漿塗佈於該金屬基層。
- 如請求項3所述之製造方法,其中該陶瓷漿黏度為500至5000cps。
- 如請求項3所述之製造方法,更進一步地,該陶瓷漿塗佈於該金屬基層後,可經預烤形成半固態之陶瓷漿膜,該半固態之陶瓷漿膜為該尚未燒結硬化之陶瓷層。
- 如請求項5所述之製造方法,該半固態之陶瓷漿膜為5000至25000cps。
- 如請求項1或2所述之製造方法,其中,該金屬線路之表面形成的方法包含噴墨印刷法、網印印刷法、平版印刷法、雷射金屬沉積3D列印或電子束3D列印。
- 如請求項7所述之製造方法,其中,該金屬線路之表面形成的方法包含雷射金屬沉積3D列印或電子束3D列印。
- 如請求項1或2所述之製造方法中,該金屬基層可為選自任一項或二種以上由鋁、鋁合金、銅及銅合金所組成之群組。
- 一種電子裝置,其包含由請求項1至9任一項所述之製造方法所獲得之金屬陶瓷積層散熱基板。
- 一種發光二極體,其包含由請求項1至9任一項所述之製造方法所獲得之金屬陶瓷積層散熱基板。
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