Controllably-Formed Brazing Structures for Thermal Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing techniques for applying powdered materials to substrates are limited in their ability to form user-definable three-dimensional structures and fail to efficiently control the spacing and brazing of substrates, leading to potential thermal shorts and excessive use of expensive brazing materials.
Innovation Solution
A process combining powder deposition and laser curing technology, using a mixture of metallic and polymer binder materials with aerogel, allowing for controlled deposition and sintering of structures that span gaps between substrates, enabling precise spacing and reduced brazing material usage, while allowing for bending and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional powder coating techniques are used to apply powdered materials to substrates, then material application is achieved, but the ability to form user-definable three-dimensional structures with precise spacing is limited
Solution Approach 1:
The patent divides the powder mixture into distinct functional components: binder particles, aerogel particles, and metallic brazing material particles. This segmentation allows each component to perform its specific function - the binder provides structural framework, aerogel provides thermal insulation with precise spacing, and metallic particles enable brazing - thereby achieving both precise spacing control and three-dimensional structure formation
Solution Approach 2:
The invention uses a composite powder mixture containing multiple material types (polymer binder, aerogel, and metallic particles) that work together to achieve functions that single materials cannot provide. The composite structure enables simultaneous formation of three-dimensional shapes, precise spacing maintenance, thermal insulation, and brazing capability
2Reliability
If conventional brazing methods are used to join substrates, then substrates are joined, but thermal shorts occur and excessive brazing material is used
Solution Approach 1:
The patent applies brazing material locally only at the edges or specific regions where substrate joining is required, rather than filling the entire gap. The aerogel-binder composite fills the remaining space to maintain spacing and provide thermal insulation. This local application of brazing material prevents thermal shorts while minimizing material consumption
Solution Approach 2:
The aerogel-binder composite acts as an intermediary material between the substrates, maintaining precise spacing and providing thermal insulation while allowing controlled brazing at specific locations. This intermediary structure prevents direct thermal contact between substrates while enabling reliable joining where needed
3Loss of substance
If high power laser applications are used for additive manufacturing, then metal and ceramic materials are welded onto substrates, but brazing material usage cannot be controlled and costs increase
Solution Approach 1:
The patent changes the laser processing parameters from high-power welding conditions to lower-power sintering conditions. The binder material is designed to sinter at lower temperatures, allowing the use of comparatively low power lasers. This parameter change enables precise control of brazing material distribution while reducing energy consumption and allowing step-wise deposition
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
Enables the formation of user-defined three-dimensional structures with precise spacing and reduced thermal conductivity, minimizing thermal shorts and brazing material usage, and allowing for efficient brazing of substrates with controlled dimensions and shapes.
Implementation Method 1
laser deposition technology techniques relate to application of powder materials to deposit coatings on parts
Implementation Method 2
applying and sintered onto a substrate
Implementation Method 3
use of an aerogel allows for controllably—and precisely—spacing surfaces of brazed parts so as to reduce or even avoid thermal shorts between surfaces
Implementation Method 4
a user may apply to a substrate a composition that includes a binder and an aerogel
Implementation Method 5
the binder (e.g., polymer particles) acts to maintain aerogel material (e.g., in particulate form) in position
Implementation Method 6
further processing may be performed so as to braze the two substrates together by brazing a material (e.g., metallic particulates)
Data Source
AI summary
The present disclosure provides compositions and methods for forming three-dimensional structures atop substrates. These structures may be formed and processed so as to braze together two substrates. The structures may be controllably formed in three dimensions so as to accommodate virtually any substrate geometry or configuration. The structures may also be disposed so as to maintain spacing between two surfaces.