Ceramic Metallization via Silver Layer on Nickel
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing ceramic metallization in ceramic metal transitions for high-voltage applications require the use of brazing foils, which complicates the process and increases costs, especially in achieving a gas-tight connection in vacuum interrupters.
Innovation Solution
A method that replaces the use of brazing foils by applying a silver (Ag) layer on top of the nickel (Ni) layer, followed by brazing or tempering to connect the metal part, eliminating the need for additional foils and allowing for in-situ alloying under vacuum or inert gas environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brazing foils are used to connect the metal part to the ceramic body, then a gas-tight connection is achieved, but the manufacturing process becomes more complex and costs increase
Solution Approach 1:
The patent removes the brazing foil from the metallization layer structure, replacing it with a direct brazeable Ni layer on the ceramic. This extraction of the intermediate brazing foil simplifies the overall structure while maintaining the gas-tight connection function through the Ni layer's inherent brazing capability.
Solution Approach 2:
The Ni layer is given multiple functions: it serves as both the brazeable surface for direct connection to the metal part and as part of the gas-tight sealing structure. This multi-functionality eliminates the need for separate brazing foils, reducing manufacturing complexity while maintaining reliability.
2Reliability
If brazing foils are used to connect the metal part to the ceramic body, then a gas-tight connection is achieved, but manufacturing costs increase
Solution Approach 1:
By removing the brazing foil component from the assembly, the patent directly reduces material costs and simplifies the supply chain. The Ni layer's inherent brazing properties replace the need for additional brazing foil materials, lowering overall manufacturing costs while maintaining the gas-tight connection.
Solution Approach 2:
The patent eliminates the brazing foil as a separate consumable material, reducing waste and material handling costs. The Ni layer serves as the permanent brazeable surface, eliminating the need for additional brazing foils that would otherwise be discarded after use.
3Ease of manufacture
If a standard MoMn and Ni layer structure is used, then the ceramic body is covered with functional layers, but additional brazing foils are required on both sides
Solution Approach 1:
The Ni layer is designed to serve dual purposes: providing the brazeable surface for direct metal-to-ceramic connection and forming part of the gas-tight sealing structure. This eliminates the need for separate brazing foils on both sides of the ceramic body, reducing component count while maintaining manufacturing ease.
Solution Approach 2:
The patent merges the function of the Ni layer with the brazing interface function, combining the protective/corrosion-resistant Ni layer with the brazeable surface requirement. This consolidation eliminates the need for separate brazing foils, reducing the number of components while maintaining ease of manufacture.
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
This approach simplifies the manufacturing process, reduces costs by eliminating the need for brazing foils, and ensures a gas-tight connection in ceramic metal transitions, particularly in high-voltage devices like vacuum interrupters.
Implementation Method 1
The next step is to deposit a silver (Ag) layer (3) on top of it
Implementation Method 2
Then follows the metal part, which will be brazed then to the ceramic body in the region of the aforesaid layers
Implementation Method 3
The brazing process is done during the standard manufacturing process here the degassing process of the components and at the latest step, the brazing process
Data Source
AI summary
A method of manufacture of a ceramic metallization for ceramic metal transition, and ceramic metal transition itself, for the use in low, medium and high-voltage techniques, which may avoid a brazing foil, and/or overcome problems with the use of thin brazing foils, and/or to make the manufacture easier, but also more effective, wherein, on top of the Ni-layer will be placed an Ag-layer as a third layer, and then the metal part will be laid on top and connected by brazing or tempering.