Foil Joining via Vacuum Pressure and Thermal Bonding
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Solution Overview
Problem
Existing methods for joining foil-like or membrane-like parts to structural parts in microfluidics lack precision and reliability, especially as dimensions decrease, leading to potential misalignment and slippage, which complicates filtration and separation processes.
Innovation Solution
A method involving the application of reduced pressure to secure the foil-like or membrane-like part, followed by thermal joining under controlled heat and pressure, using a tool with a raised edge to facilitate precise alignment and a separating layer to prevent adherence, along with a device design that enables translational movement for accurate placement and efficient automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional joining methods are used for foil-like parts in microfluidics, then the process can be simple, but the precision and reliability of joining deteriorates as dimensions decrease
Solution Approach 1:
The foil-like part is secured to the support structure before the actual joining operation using reduced pressure. This preliminary securing action prevents misalignment and slippage during subsequent thermal joining, ensuring precise placement without requiring complex alignment mechanisms.
Solution Approach 2:
Reduced pressure is applied through a channel system to secure the foil-like part to the support structure. The pneumatic action holds the foil in place during processing, providing reliable positioning without mechanical clamps or complex fastening devices.
2Manufacturing precision
If reduced pressure is applied to secure the foil-like part, then placement precision improves, but the device complexity increases due to additional pressure control systems
Solution Approach 1:
The support structure serves multiple functions: it provides mechanical support, contains the channel for reduced pressure application, and acts as the final substrate for joining the foil-like part. This multi-functionality eliminates the need for separate alignment fixtures or clamping mechanisms.
Solution Approach 2:
The channel for applying reduced pressure is integrated directly into the support structure. The support structure and pressure application system are merged into a single component, reducing overall device complexity while maintaining precise placement capability.
3Reliability
If thermal joining is used to join the foil-like part to the structural part, then joining reliability improves, but the risk of foil adherence to the joining tool increases
Solution Approach 1:
A separating layer is introduced between the foil-like part and the joining tool during thermal joining. This intermediary layer prevents the foil from adhering to the heated tool surface while allowing thermal energy to transfer through for successful joining of the foil to the structural part.
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
Ensures precise and reliable joining of foil-like or membrane-like parts to structural parts, preventing slippage and misalignment, while allowing for efficient automation and clean cut edges, enhancing the reliability of filtration and separation processes in microfluidics and other applications.
Implementation Method 1
The channel (5, 11) is connected to a vacuum source or a compressed air source, in order that a reduced pressure or an excess pressure can be generated
Implementation Method 2
thermal joining under controlled heat and pressure, using a tool with a raised edge
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for joining at least one foil-like or membrane-like part to a structural part (9), wherein the foil-like or membrane-like part is separated by means of a tool (2) from a semi-finished product (3) and is held on the tool (2) by applying a reduced pressure, and wherein the foil-like or membrane-like part is placed on the structural part (9), and is in turn held on this (9) and joined to this (9) by applying a reduced pressure. By means of the method a precise, reliable and readily automatable joining of a foil-like or membrane-like part to a structural part (9) is possible. A device (1) is also proposed, with which the method according to the invention can readily be carried out.