Cermet substrate with glass adhesion component

Claim 2

The process of forming a composite material, comprising the steps of: providing a mixture of from about 25 to about 80 volume % of metallic material in the form of particles, from an effective amount up to about 10 volume % of binder in the form of particles of glass, and the balance essentially ceramic particles; mixing said glass particles with said ceramic particles whereby said ceramic particles are coated with said glass particles; mixing the glass coated ceramic particles with said metallic particles; compacting said mixture; and heat treating the compacted mixture to form a matrix comprising the metallic material with said glass coated ceramic particles distributed within said matrix.

Claim 3

The process of claim 1 further including the steps of: selecting the metallic particles having a size from about 3 to about 100 microns; selecting said glass particles having a size from about 3 to about 25 microns; selecting said ceramic particles having a size from about 10 to about 100 microns; and selecting said ceramic particles of a larger size than said metallic particles.

Claim 4

The process of claim 2 further including the step of selecting said metallic material from the group consisting of aluminum, copper, nickel, titanium, chromium, iron, silver, gold and alloys thereof.

Claim 5

The process of claim 3 further including the step of selecting said ceramic material from the group consisting of Al 2 O 3 , AlN, SiC, BeO, TiO 2 , ZrO 2 , MgO, BN, Si 3 N 4 and mixtures thereof.

Claim 6

The process of claim 4 further including the step of selecting said glass from the group consisting of silicate, borosilicate, lead borate, phosphate, lead-silicate, soda-lime-silica, lead-zinc-borate and zinc borosilicate glasses.

Claim 7

The process of claim 5 further including the step of selecting said glass binder having a softening temperature in the range of about 350° to about 1200° C.

Claim 8

The process of claim 6 further including the step of selecting said glass having a CTE of about 60×10 -7 to about 170×10 -7 in/in/°C.

Claim 9

The process of claim 7 further including the step of maintaining said compacted mixture at a temperature of about 600° to about 750° C. for a time of about 8 to about 100 hours.

Claim 10

An article of commerce in accordance with the process of claim 1.

Claim 11

An article of commerce in accordance with the process of claim 4.

Claim 12

The process of forming a composite material comprising the steps of: providing a mixture from about 25 to about 80 volume % of metallic material in the form of particles, from an effective amount up to about 10 volume % of binder in the form of particles of glass, and the balance essentially ceramic particles; mixing said particles of glass with said ceramic particles whereby said ceramic particles are coated with said glass particles; heating the glass coated ceramic particles to soften the glass; cooling the heated glass coated ceramic particles to fuse the glass to the ceramic particles; grinding the fused glass coated ceramic into particle form; mixing the glass coated ceramic particles with said metallic parrticles; compacting said mixture; and heat treating the compacted mixture to form a matrix comprising the metallic material with said glass coated ceramic particles distributed therein.

Claim 13

The process of forming a composite material comprising the steps of: providing a mixture from about 25 to about 80 volume % of metallic material in the form of particles, from an effective amount up to about 10 volume % of binder in the form of particles of glass, and the balance essentially ceramic particles; mixing said particles of glass with said ceramic particles whereby said ceramic particles are coated with said glass particles; heating the glass coated ceramic particles to soften the glass; cooling the heated glass coated ceramic particles to fuse the glass to the ceramic particles; grinding the fused glass coated ceramic into particle form; mixing the glass coated ceramic particles with said metallic parrticles; compacting said mixture; and heat treating the compacted mixture to form a matrix comprising the metallic material with said glass coated ceramic particles distributed therein.

Claim 14

The process of claim 11 further including the steps of: selecting the metallic particles having a size from about 3 to about 100 microns; selecting said glass particles having a size from about 3 to about 25 microns; selecting said ceramic particles having a size from about 10 to about 100 microns; and selecting said ceramic particles of a size which is greater than said metallic particles.

Claim 15

The process of claim 12 further including the step of selecting said metallic material from the group consisting of aluminum, copper, nickel, titanium, chromium, iron, silver, gold and alloys thereof.

Claim 16

The process of claim 13 further including the step of selecting said ceramic material from the group consisting of Al 2 O 3 , AlN, SiC, BeO, TiO 2 , ZrO 2 , MgO, BN, Si 3 N 4 and mixtures thereof.

Claim 17

The process of claim 14 further including the step of selecting said glass from the group consisting of silicate, borosilicate, lead borate, phosphate, soda-lime-silica, lead-silicate, lead-zinc-borate and zinc borosilicate glasses.

Claim 18

The process of claim 15 further including the step of selecting said glass having a CTE of about 60×10 -7 to about 170×10 -7 in/in/°C.

Claim 19

The process of claim 16 further including the step of heat treating said compacted mixture at a temperature of about 600° to about 750° C. for a time of about 8 to about 100 hours.

Claim 20

An article of commerce in accordance with the process of claim 11.

Claim 21

A composite material comprising: from about 25 to about 80 volume % of metallic material; from an effective amount up to about 10 volume % of glass; and the balance essentially ceramic particles; said glass bonding to both said metallic material and said ceramic particles resulting in said composite material having a matrix comprising said metallic material with glass coated ceramic particles distributed therein; and said ceramic particles being selected from the group consisting of Al 2 O 3 , AlN 2 , SiC, BeO, TiO 2 , ZrO 2 , MgO, BN, Si 3 N 4 , and mixtures thereof.

Claim 22

A composite material comprising: from about 25 to about 80 volume % of metallic material; from an effective amount up to about 10 volume % of glass; and the balance essentially ceramic particles; said glass bonding to both said metallic material and said ceramic particles resulting in said composite material having a matrix comprising said metallic material with glass coated ceramic particles distributed therein; and said ceramic particles being selected from the group consisting of Al 2 O 3 , AlN 2 , SiC, BeO, TiO 2 , ZrO 2 , MgO, BN, Si 3 N 4 , and mixtures thereof.

Claim 23

The composite of claim 19 including said ceramic particles having a size from between about 10 to about 100 microns.

Claim 24

The composite of claim 20 further including said coating of glass being selected from the group consisting of silicate, borosilicate, lead borate, phosphate, soda-lime-silicate, lead-silicate, lead-zinc-borate and zinc borosilicate glasses.

Claim 25

The composite of claim 21 wherein said matrix with the glass coated ceramic particles distributed therein has a coefficient of thermal expansion of between about 140×10 -7 to about 170×10 -7 in/in/°C., a thermal conductivity of at least about 50 W/m-°K., and a compressive elastic modulus of at least about 20×10 6 psi.

Claim 26

The composite of claim 22 further including a substrate and a cover both formed of said composite; a metallic leadframe; and a glass bonding said cover to said substrate with said leadframe therebetween to form a casing adapted to receive a semiconductor device.

Claim 27

A composite material comprising: from about 25 to about 80 volume % of metallic material; from an effective amount up to about 10 volume % of glass; and the balance essentilly ceramic particles; said glass being coated about said ceramic particles; and said glass coated particles being blended with said metallic material so that said glass bonds to both said metallic material and said ceramic particles, resulting in said composite material having a matrix comprising said metallic material with glass coated ceramic particles distributed therein.

Claim 28

A composite material comprising: from about 25 to about 80 volume % of metallic material; from an effective amount up to about 10 volume % of glass; and the balance essentilly ceramic particles; said glass being coated about said ceramic particles; and said glass coated particles being blended with said metallic material so that said glass bonds to both said metallic material and said ceramic particles, resulting in said composite material having a matrix comprising said metallic material with glass coated ceramic particles distributed therein.

Claim 29

The composite of claim 24 further including said ceramic particles being selected from the group consisting of Al 2 O 3 , AlN 2 , SiC, BeO, TiO 2 , ZrO 2 , MgO, BN, Si 3 N 4 , and mixtures thereof.

Claim 30

The composite of claim 25 including said ceramic particles having a size from between about 10 to about 100 microns.

Claim 31

The composite of claim 26 further including said coating of glass being selected from the group consisting of silicate, borosilicate, lead borate, phosphate, soda-lime-silicate, lead-silicate, lead-zinc-borate, and zinc borosilicate glasses.

Claim 32

The composite of claim 27 wherein said matrix with the glass coated ceramic particles distributed therein has a coefficient of thermal expansion of between about 140×10 -7 to about 170×10 -7 in/in/°C., a thermal conductivity of at least about 50 W/m-°K., and a compressive elastic modulus of at least about 20×10 6 psi.

Claim 33

The composite of claim 28 further including a substrate and a cover both formed of said composite; a metallic leadframe; and a glass bonding said cover to said substrate with said leadframe therebetween to form a casing adapted to receive a semiconductor device.