Hydraulic Sintering for Uniform Joining Partner Bonding
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Solution Overview
Problem
Existing sintering methods for connecting joining partners face issues such as uneven force distribution, high costs, contamination, and inhomogeneous porosity in the connection layer, due to limitations in pressure distribution and sealing requirements.
Innovation Solution
A method involving a joining chamber where a first joining partner is arranged with a pre-layer, and a second joining partner is placed on top, with a liquid polymer filling the chamber to apply pressure and form a connecting layer between the partners, ensuring a firm substance-to-substance bond, while the liquid is solidified under pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional sintering methods with mechanical pressure are used, then joining partners can be connected, but uneven force distribution occurs
Solution Approach 1:
The patent applies hydraulic pressure through a liquid medium (water or oil) to transmit force uniformly to all joining partners in the chamber. The liquid pressure distributes the connecting force evenly across the entire surface area, eliminating the uneven force distribution problems associated with mechanical pressure application methods.
2Stress or pressure
If complex sealing systems are implemented to maintain pressure, then pressure can be maintained, but device complexity and costs increase
Solution Approach 1:
The patent uses a liquid-filled chamber where the liquid itself serves as both the pressure transmission medium and the sealing medium. The liquid is contained in a closed chamber that can be pressurized, eliminating the need for complex mechanical sealing systems while maintaining effective pressure for the sintering process.
3Strength
If mechanical pressing is used to compress the pre-layer, then connection can be formed, but contamination of seals and connecting layer occurs
Solution Approach 1:
The patent replaces direct mechanical contact pressing with hydraulic pressure transmission through liquid. The liquid medium transmits pressure uniformly without physical contact between the pressing mechanism and the joining partners, preventing contamination of seals and the connecting layer while still achieving the necessary compression strength.
4Strength
If high pressure is applied to achieve firm bonding, then connection quality improves, but inhomogeneous porosity is created in the connection layer
Solution Approach 1:
The patent uses hydraulic pressure to apply high compressive force uniformly throughout the pre-layer and connecting layer. The liquid pressure distributes force evenly in all directions, achieving firm bonding while maintaining homogeneous porosity distribution, unlike unidirectional mechanical pressing that creates density variations.
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 method achieves a homogeneous pressure distribution, reduces costs by eliminating the need for complex seals, and ensures a consistent, high-quality connection layer with improved porosity, overcoming the limitations of traditional sintering processes.
Implementation Method 1
filling the joining chamber with a liquid, thereby applying a pressure to the joining partners such that the second joining partner is pressed onto the first joining partner, thereby compressing the pre-layer
Implementation Method 2
The liquid comprises a liquid polymer, and the liquid is solidified or hardened while applying pressure to the joining partners
Data Source
Figure 1~2B
Figure 2C~3
Figure 4~5B
AI summary
A method includes arranging a first joining partner in a joining chamber, the first joining partner comprising a first surface and a second surface opposite the first surface, the first surface facing a bottom surface of the joining chamber, arranging a second joining partner on the second surface of the first joining partner, with a first pre-layer being arranged between the first joining partner and the second joining partner, filling the joining chamber with a liquid, thereby applying a pressure to the joining partners such that the second joining partner is pressed onto the first joining partner, thereby compressing the pre-layer resulting in a connecting layer which forms a firm substance-to-substance bond between the first joining partner and the second joining partner.