Thermal pyrolytic graphite enhanced components

摘要

A thermally conductive composite material, a thermal transfer device made of the material, and a method for making the material are disclosed. Apertures or depressions are formed in aluminum or aluminum alloy. Plugs are formed of thermal pyrolytic graphite. An amount of silicon sufficient for liquid interface diffusion bonding is applied, for example by vapor deposition or use of aluminum silicon alloy foil. The plugs are inserted in the apertures or depressions. Bonding energy is applied, for example by applying pressure and heat using a hot isostatic press. The thermal pyrolytic graphite, aluminum or aluminum alloy and silicon form a eutectic alloy. As a result, the plugs are bonded into the apertures or depressions. The composite material can be machined to produce finished devices such as the thermal transfer device. Thermally conductive planes of the thermal pyrolytic graphite plugs may be aligned in parallel to present a thermal conduction path.

主权项

1. A thermally conductive composite material comprising:
an aluminum or aluminum alloy member; discrete plugs of thermal pyrolytic graphite embedded within a plurality of apertures formed in the aluminum or aluminum alloy member; and an eutectic alloy interface produced by a process comprising a thin layer of silicon of an interface location of said aluminum or aluminum alloy member and said discrete plugs of thermal pyrolytic graphite and then using elevated temperature and pressure to bond said aluminum or aluminum alloy member and said discrete plugs of thermal pyrolytic graphite together at said eutectic alloy interface securing the plugs to the aluminum or aluminum alloy member and formed by the aluminum or aluminum alloy, the thermal pyrolytic graphite and silicon, total residual silicon material after elevated temperature diffusion bonding limited to a thin region of at most 50 microns around each graphite plug.