臺灣博碩士論文加值系統

利用無壓真空液相燒結製程製備銅基鑽石複材，並獲得高熱傳導係數且熱膨脹係數介於4-7 ppm/K的散熱複材，適當的平整處理之後與常見之電路基板進行接合。
在銅基材中添加單一活性元素鋯以提升潤濕性，並探討活性元素添加量對複材熱性質的影響。實驗中的複材熱傳導係數最高可達608 W/mK，其熱膨脹係數為6.4 ppm/K，介於電子元件的範圍內。本製程簡單、模具亦無損耗問題，在成本考量上極具優勢；利用添加銅鋯薄片的平整處理方式，可有效將複材的表面粗糙度減少一個數量級以上。而實驗中所設計的接合流程能夠有效將銅基複材與電路基板做出完整的接合封裝，並具有良好的拉伸強度。其封裝結構的熱性質表現最優異為銀膠接合氮化鋁組，其熱傳導值最高可達174 W/mK。銀膠組普遍熱性質良好、環氧膠組具有優異的拉伸強度，大於8.34 MPa；石墨膠組的拉伸強度約在1 MPa上下，可利用其來分析拉伸斷面上的膠分布，並推論接合中最脆弱的接合位置。氮化鋁與氧化鋁試片組由膠體中間斷開；而矽試片組屬於另一系統，由膠體與基板界面斷開。200 °C、150 次的高溫熱循環試驗中，發現銅鋯薄片添加可延後複材熱性質的劣化，其中環氧膠的氧化鋁組無衰退情形出現。而85 °C、1000 次的低溫熱循環試驗中，接合封裝的銀膠組可以通過測試，顯示其在實際使用條件下能有良好的可靠性，具有商業潛力。

Pressureless liquid phase sintering process was adopted for the fabrication of diamond/Cu composites. After suitable surface treatment these composites were joined with AlN, Si, and Al2O3 substrates by silver, graphite, and epoxy gels. The results show that adding minor active Zr element to enhance the wettability between Cu and diamond, the composites with a high thermal conductivity of 608 W/mK and CTE of 6.4 ppm/K can be achieved by using 300 μm diamonds with the volume fraction of 50 vol%. One order of surface roughness can be reduced through attaching a Cu/Zr flake to the composites before sintering. Packages joined by the silver gel have best performance, reaching 210 W/mK; those joined by epoxy shows excellent tensile strength, larger than 8.34 MPa. The tensile strength of graphite gel is around 1 MPa, providing a suitable condition to observe the distribution of the gel on the fracture surface. In thermal cycle tests carried out at 200 °C with 150 cycles, it was found that Cu/Zr flake addition can postpone the degradation of thermal properties of the composites, and the alumina package joined by epoxy gel has good reliability. While in thermal cycle tests carried out at 80 °C with 1000 cycles, packages joined by silver gel shows great reliability in normal circumstances, showing great commercial potential.

摘 要 I
Abstract II
誌 謝 III
目 錄 V
圖目錄 IX
表目錄 XVII
壹、 前言 1
貳、 文獻回顧 3
2.1. 散熱材料的重要性 3
2.2. 散熱材料的發展 5
2.2.1. 傳統散熱材料 6
2.2.2. 先進散熱材料 8
2.3. 鑽石金屬基複合材料 11
2.3.1. 常見製程 11
2.3.2. 理論性質 16
2.4. 影響金屬基鑽石複材熱性質的因素 22
2.4.1. 鑽石與金屬基材的界面潤濕問題 22
2.4.2. 鑽石粒徑與體積分率 24
2.4.3. 界面層厚度 25
2.4.4. 鑽石晶面差異 27
2.5. 熱循環測試 29
2.5.1. 熱循環測試之目的及原理 29
2.5.2. 熱循環測試的規範 30
2.6. 熱界面材料 32
2.6.1. 熱界面材料的分類與特性 32
2.6.2. 熱界面材料與接觸熱阻的關係 34
2.7. 電子封裝 38
2.7.1. 電子封裝層級 39
2.7.2. 常見電路基板 41
參、 實驗方法與步驟 43
3.1. 實驗設計與流程 43
3.1.1. 成份來源及其性質 43
3.1.2. 實驗設計與原理 46
3.1.3. 實驗規劃 47
3.1.4. 實驗參數 50
3.2. 乾式混粉與冷壓成型 51
3.3. 水平爐管真空液相燒結 51
3.4. 複合材料與接合封裝的性質與分析 54
3.4.1. 微結構觀察 54
3.4.2. 緻密度量測 54
3.4.3. 熱傳導係數量測 55
3.4.4. 熱膨脹係數量測 56
3.4.5. 熱循環測試 56
3.4.6. 表面粗糙度量測 60
3.4.7. 基板接合 61
3.4.8. 拉伸測試 62
肆、 結果與討論 63
4.1. 乾式混粉前粉末觀察 63
4.2. 接合前材料的熱性質 65
4.2.1. 活性元素添加對銅鋯基鑽石複材的熱性質影響 65
4.2.2. 基板的熱性質 74
4.3. 平整處理 75
4.3.1. 軟焊 77
4.3.2. 錫鈦薄片添加 79
4.3.3. 銅鋯薄片添加 83
4.4. 接合封裝之熱傳導係數量測 85
4.5. 接合封裝之界面熱阻理論分析 93
4.6. 熱循環測試結果 98
4.6.1. 銅鋯基鑽石複材的熱循環測試 99
4.6.2. 接合封裝的熱循環測試 104
4.7. 接合封裝之拉伸測試 111
4.7.1. 接合封裝之拉伸強度 111
4.7.2. 接合封裝之拉伸斷面分析 114
4.7.3. 接合封裝熱循環測試後的拉伸斷面分析 122
伍、 結論 136
陸、 建議未來研究方向 139
柒、 參考文獻 140

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