Aluminum bonding member and method for producing same

Abstract

There is provided an aluminum bonding member capable of being simply and inexpensively produced and capable of being used as a cooling member having a high cooling power. The aluminum bonding member 10 has an aluminum member 12 of aluminum or an aluminum alloy exposed to the outside, and a tubular member 14 of a material which does not melt at a temperature close to the melting point of aluminum or the aluminum alloy. Both of the opening end portions of the tubular member 14 are open to the outside of the aluminum member 12. A portion of the tubular member 14 between the opening end portions extends in the aluminum member 12, and the outer peripheral surface of the portion of the tubular member 14 extending in the aluminum member 12 is bonded directly to the aluminum member 12.

1 . An aluminum bonding member comprising: 
 an aluminum member of aluminum or an aluminum alloy; and    a tubular member extending in said aluminum member, both of opening end portions of said tubular member being open to the outside of said aluminum member,    wherein said tubular member is made of a material which does not melt at a temperature close to a melting point of aluminum or the aluminum alloy, and    at least part of an outer peripheral surface of a portion of said tubular member extending in said aluminum member contacts said aluminum member.    
     
     
         2 . An aluminum bonding member as set forth in  claim 1 , wherein said at least part of the outer peripheral surface of the portion of the tubular member extending in the aluminum member contacts said aluminum member to be bonded thereto.  
     
     
         3 . An aluminum bonding member as set forth in  claim 1 , wherein the whole outer peripheral surface of said portion of the tubular member extending in the aluminum member contacts said aluminum member to be bonded thereto.  
     
     
         4 . An aluminum bonding member as set forth in  claim 1 , wherein said tubular member is made of a metal containing at least one element, which is selected from the group consisting of tungsten, molybdenum, titanium, zirconium, iron, copper and nickel, as a main component.  
     
     
         5 . An aluminum bonding member as set forth in  claim 1 , wherein said tubular member is made of a ceramic or carbon.  
     
     
         6 . An aluminum bonding member as set forth in  claim 1 , wherein said tubular member is made of stainless, SKD or an molybdenum alloy.  
     
     
         7 . An aluminum bonding member as set forth in  claim 1 , wherein said tubular member is made of a high-melting-point sintered material.  
     
     
         8 . An aluminum bonding member as set forth in  claim 7 , wherein said high-melting-point sintered material is a molybdenum sintered material or a tungsten sintered material.  
     
     
         9 . An aluminum bonding member as set forth in  claim 1 , wherein a ceramic substrate, which has a metal circuit plate bonded thereto, is bonded to one side of the aluminum bonding member.  
     
     
         10 . An aluminum bonding member as set forth in  claim 1 , wherein ceramic substrates, each of which has a metal circuit plate bonded thereto, are bonded to both sides of the aluminum bonding member, respectively.  
     
     
         11 . An aluminum bonding member as set forth in  claim 1 , which is used as a cooling member.  
     
     
         12 . A method for producing an aluminum bonding member, said method comprising the steps of: 
 preparing a tubular member of a material which does not melt at a temperature close to a melting point of aluminum or an aluminum alloy;    putting said tubular member in a die so that opening end portions of the tubular member are open to the outside of the die;    injecting a molten metal of aluminum or the aluminum alloy into said die; and    cooling and solidifying the injected molten metal to cause a portion of said tubular member in said die to contact a solid aluminum member.    
     
     
         13 . A method for producing an aluminum bonding member as set forth in  claim 12 , wherein said portion of said tubular member in the die is caused to contact said solid aluminum member to be bonded thereto.  
     
     
         14 . A method for producing an aluminum bonding member as set forth in  claim 13 , which further comprises a step of arranging a metal/ceramic circuit board, which has a metal circuit plate bonded to a ceramic substrate, on said die so as to close an opening portion formed in a top face of the die, before injecting said molten metal, so that said metal/ceramic circuit board contacts said solid aluminum member to be bonded thereto when said portion of the tubular member in the die is caused to contact said solid aluminum member to be bonded thereto.  
     
     
         15 . A method for producing an aluminum bonding member as set forth in  claim 13 , which further comprises a step of arranging a ceramic substrate in said die before injecting said molten metal, so that said solid aluminum member is caused to contact to one side of said ceramic substrate to be bonded thereto while an aluminum circuit plate is caused to contact the other side of said ceramic substrate to be bonded thereto when said portion of the tubular member in the die is caused to contact said solid aluminum member to be bonded thereto.  
     
     
         16 . A method for producing an aluminum member as set forth in  claim 15 , wherein said ceramic substrate is caused to contact each of both sides of said solid aluminum member to be bonded thereto.  
     
     
         17 . A power module wherein a metal circuit plate is bonded to one side of a ceramic substrate, and an aluminum bonding member as set forth in  claim 1  is bonded to the other side of said ceramic substrate.