Clamping Fixture Aperture for Void-Reduced Thermal Joining

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Solution Overview

Problem

Traditional thermal joining processes face challenges in achieving proper contact and alignment of materials, leading to inefficiencies and increased voids at the joined interface, particularly when joining metal-containing materials.

Innovation Solution

The use of a clamping fixture with an aperture that compresses materials against a substrate, enhancing contact and alignment through selective attachment, allowing for improved thermal joining by applying compressive force and heat access.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional thermal joining processes are used without clamping fixtures, then the process is simpler, but contact and alignment of materials are poor leading to increased voids at the joined interface

Engineering Contradiction:

Improvealignment of materialsVSAvoidjoining system structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

A clamping fixture acts as an intermediary device between the heating element and the materials to be joined. The fixture includes a clamping member with an aperture that positions and compresses the materials, ensuring proper alignment and contact while allowing thermal energy to pass through the aperture to the joint interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The joining system is segmented into distinct functional components: a clamping fixture for mechanical compression and alignment, a substrate for support, and a heating element for thermal joining. This segmentation allows each component to perform its specific function optimally, with the clamping fixture specifically designed to address alignment and contact issues.

Inventive Principle:

Principle #1Segmentation

2Reliability

If materials are compressed without proper alignment, then compression can be applied, but voids increase at the joined interface reducing joint quality

Engineering Contradiction:

Improvejoint qualityVSAvoidmaterial positioning

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The clamping fixture performs preliminary alignment and positioning of the materials before thermal joining occurs. The aperture in the clamping member pre-positions the materials in the correct alignment, and the compression force is applied in advance to ensure intimate contact between the material surfaces before heating begins.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system replaces manual or less precise mechanical positioning methods with a structured clamping fixture that provides consistent, repeatable alignment through its aperture design and compression mechanism, ensuring reliable material positioning for each joining operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If clamping fixture with aperture is used to compress and align materials, then contact and alignment improve, but the device structure becomes more complex

Engineering Contradiction:

Improvecontact and alignmentVSAvoidclamping fixture structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The clamping fixture is designed as a multi-functional device that simultaneously performs compression, alignment, and positioning functions through its aperture structure. This universal design consolidates multiple functions into a single component, reducing the need for separate alignment tools and compression devices.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The clamping fixture applies compression and alignment locally at the aperture region where the materials need to be joined. The aperture provides localized contact and alignment precisely where needed, rather than requiring complex global positioning systems for the entire workpiece.

Inventive Principle:

Principle #3Local quality

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 reduces voids at the joined interface, enhances electrical connections, and facilitates efficient thermal joining of materials by ensuring proper alignment and contact, thereby improving the quality of the joined materials.

Implementation Method 1

the clamping fixture is configured to compress the first material against the second material

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

thermally joining the first material and the second material by heating the first material through an aperture extending from a first surface of the clamping fixture to a second surface of the clamping fixture opposite the first surface

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11826861B1Joining systems, clamping fixtures, and related systems and methods

Publication Date: 2023.11.28 SION POWER CORP

AI summary

Joining systems, clamping fixtures, and related systems and methods are generally described.