Flexible Reactive Planar Structure for Large-Area Joining
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Solution Overview
Problem
Existing nanofoils for joining metallic components are limited by their small maximum area extent of about 600 cm2, brittleness, and inability to handle non-flat joint faces, making them economically and practically unsuitable for large or complex joint applications.
Innovation Solution
A flexible reactive planar structure formed by spatially arranged reaction strands with a cylindrical core and thin, exothermic coatings, allowing for large-area, curved surface joining and integration into composite components, using methods like weaving or interlacing, and capable of producing a substance-to-substance bond through exothermic chemical reactions triggered by localized heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional nanofoils are used for joining metallic components, then substance-to-substance bond can be achieved, but the area extent is limited to maximum of about 600 cm2
Solution Approach 1:
The joining structure is divided into multiple separate nanofoil strips that can be individually manufactured and then assembled together to form a larger area configuration. This segmentation allows each strip to be produced within the feasible manufacturing area limit while the collective assembly achieves the required large area coverage for extensive joint faces.
2Adaptability or versatility
If traditional nanofoils are used for joining, then level joint faces can be joined, but curved or non-flat joint faces cannot be accommodated due to brittleness
Solution Approach 1:
The rigid nanofoil structure is replaced with a flexible cable assembly that can dynamically adapt to curved and non-flat joint faces. The cable's flexibility allows it to conform to various surface geometries while maintaining structural integrity through its construction from multiple stranded wires rather than a brittle solid sheet.
Solution Approach 2:
The brittle solid nanofoil is replaced with a flexible cable structure that functions as a thin-walled flexible element. This cable can bend and conform to curved surfaces while maintaining its structural properties, enabling joining of non-flat joint faces that would be inaccessible to rigid nanofoil strips.
3Strength
If high temperature is applied to large-area joint regions for joining, then substance-to-substance bond can be achieved, but thermal impairment of components occurs
Solution Approach 1:
The external thermal field required for traditional joining is replaced by an internal chemical energy source embedded within the cable structure itself. The exothermic reaction occurs locally at the cable position, providing the necessary heat for joining without requiring external heating equipment that would expose the entire large-area joint region to harmful thermal fields.
Solution Approach 2:
The joining system becomes self-sufficient by incorporating the heat source directly into the joining structure. The exothermic reaction within the cable generates its own heat for the joining process, eliminating the need for external heating systems and thereby preventing thermal impairment of the broader component areas that would result from external high-temperature application.
4Area of stationary object
If external heat sources are used for large-area joining, then joining can be achieved, but the process becomes complex and costly
Solution Approach 1:
Complex external thermal fields and heating equipment are replaced by a simple cable structure containing embedded exothermic reagents. This substitution dramatically simplifies the joining system for large areas, eliminating the need for complex external heating infrastructure while enabling straightforward application over extensive joint faces.
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 efficient, cost-effective, and distortion-free joining of components with complex geometries over large areas, including those difficult to access, by releasing high temperatures uniformly and maintaining mechanical reinforcement, thus overcoming the limitations of traditional nanofoils.
Implementation Method 1
an exothermic reaction can be triggered in the coating by the supply of a limited amount of heat to join the two components in a substance-to-substance bond
Implementation Method 2
this only takes place over a very short time period and is uniformly distributed over the joint face because of the limited energy density
Data Source
AI summary
The invention relates to a planar structure for joining, in particular for the material-uniting joining, of at least two components. According to the invention, the planar structure is flexible and formed by at least one reaction strand. The reaction strand comprises a preferably cylindrical core, which is provided, at least in some areas, with a coating, which is constructed with a plurality of coaxially applied layers with a small thickness. To produce the layers, two different materials are used, the layers being constructed alternately with one of the two materials. Because of the high degree of flexibility of the reactive planar structure and its arbitrary area extent, components with a complex geometry in the region of the joint faces as well as large-format components can be joined in a material-uniting manner without problems. The reactive planar structure can be produced here using the methods known from textile engineering with virtually any dimensions and, in addition, by a continuous industrial production process. Moreover, the invention relates to a method for providing a material-uniting connection between two components, in particular by means of the planar structure according to the invention.