Bonded Structure Stress Relaxation Layer

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Solution Overview

Problem

Existing bonded structures face issues with interfacial peeling due to stress caused by differences in thermal expansion between bonded members, despite the use of stress relaxation agents.

Innovation Solution

A bonded structure comprising a first bonded member, a second bonded member, and a bonding layer that includes a stress relaxation layer with chain polymers, a first bonded molecular layer, and a second bonded molecular layer, where the ends of the chain polymers bind to the bonded molecules through binding molecules or directly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a bonding layer is used to bond two members with different linear expansion coefficients, then the members can be joined together, but stress accumulates in the bonding layer causing interfacial peeling

Engineering Contradiction:

Improveinterfacial bondabilityVSAvoidresistance to interfacial peeling

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The bonding layer is segmented into three distinct functional layers: a stress relaxation layer containing chain polymers, a first bonded molecular layer, and a second bonded molecular layer. This segmentation allows each layer to perform its specific function - the stress relaxation layer absorbs thermal expansion stress while the bonded molecular layers ensure strong adhesion to the bonding surfaces, preventing interfacial peeling.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bonding layer uses a composite structure combining different materials with complementary properties. The stress relaxation layer uses chain polymers with high elasticity to absorb stress, while the bonded molecular layers use molecules with specific binding capabilities to ensure strong adhesion. This composite approach allows the bonding layer to simultaneously achieve stress relaxation and strong bonding.

Inventive Principle:

Principle #40Composite materials

2Stress or pressure

If stress relaxation agents are added to the bonding layer, then stress can be relaxed, but the interfacial bondability deteriorates due to peeling

Engineering Contradiction:

Improvestress relaxationVSAvoidinterfacial bondability

Core Design Contradiction:

Stress or pressureVSStrength

Solution Approach 1:

Different regions of the bonding layer have different local qualities tailored to their specific functions. The stress relaxation layer contains chain polymers with high elasticity for stress absorption, while the bonded molecular layers contain molecules with strong adhesion properties for bonding. This local quality differentiation allows the bonding layer to simultaneously achieve stress relaxation and strong interfacial bonding without compromise.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The bonded molecular layers act as intermediaries between the stress relaxation layer and the bonding surfaces. These layers ensure strong adhesion to the bonding surfaces while allowing the stress relaxation layer to perform its stress-absorbing function, thus mediating between the conflicting requirements of stress relaxation and interfacial bonding.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The proposed bonded structure effectively relaxes stress applied to the bonding layer, thereby suppressing interfacial peeling and enhancing interfacial bondability, even when bonded members have significantly different linear expansion coefficients.

Implementation Method 1

a stress relaxation layer containing a chain polymer

Methodology Applied

Scientific EffectStress relaxation: Stress Relaxation

Implementation Method 2

The bonding layer includes: a stress relaxation layer containing a chain polymer

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 3

a first bonded molecular layer containing a first bonded molecule bonded to the first bonding surface, and a second bonded molecular layer containing a second bonded molecule bonded to the second bonding surface

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS12221565B2Bonded structure

Publication Date: 2025.02.11 DENSO CORP

AI summary

A bonded structure includes a first bonded member having a first bonding surface, a second bonded member having a second bonding surface, and a bonding layer that bonds the first bonding surface and the second bonding surface. The bonding layer includes a stress relaxation layer containing a chain polymer, a first bonded molecular layer containing a first bonded molecule bonded to the first bonding surface, and a second bonded molecular layer containing a second bonded molecule bonded to the second bonding surface. A first end of the chain polymer is bonded to the first bonded molecule via a first binding molecule or without bonding via the first binding molecule. A second end of the chain polymer is bonded to the second bonded molecule via a second binding molecule or without bonding via the second binding molecule.