Jet Locking Joins Dissimilar Materials Without Thermal Damage
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Solution Overview
Problem
Conventional methods for joining dissimilar materials like metals and polymers, such as laser-based techniques, often rely on thermal heating, which can alter the microstructure and mechanical properties of the materials, posing challenges for effective and precise joining at smaller scales.
Innovation Solution
The method involves generating a shockwave in a first component to form a jet of material that penetrates a second component, using an ablation layer excited by a light source, such as a laser, to create a connection between the components without significant thermal alteration, employing a confinement layer to control the shockwave and a notch to direct the jet, allowing for micron-scale precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal heating methods (e.g., laser welding) are used to join dissimilar materials, then joining capability is improved, but thermal alteration and damage to materials occur
Solution Approach 1:
The patent replaces thermal-based joining mechanisms with a shockwave-based mechanical mechanism. A light source generates a shockwave that propagates through the first component, forming a high-velocity jet that penetrates the second component. This mechanical shockwave-driven jet formation and penetration process eliminates the need for thermal heating, thereby avoiding thermal alteration and damage to the materials while achieving strong joining capability.
Solution Approach 2:
The patent changes the fundamental parameter of the joining process from thermal energy to shockwave mechanical energy. By using a light source to generate a shockwave rather than heat, the process transforms the energy type and mechanism, enabling joining without thermal effects. This parameter change allows dissimilar materials to be joined without the thermal alteration that would otherwise occur.
2Strength
If conventional joining methods are used for large scale applications, then structural strength is improved, but applicability at smaller size scales deteriorates
Solution Approach 1:
The patent segments the joining process into distinct functional components: a light source generates a shockwave, the shockwave propagates through the first component, a jet forms at a specific location (notch), and the jet penetrates the second component. This segmentation allows precise control at the micron scale while maintaining structural strength, as each component can be optimized independently for its specific function.
Solution Approach 2:
The patent applies local quality by creating a jet at a specific localized region (the notch in the first component) rather than applying force or heat uniformly across the entire interface. The jet forms locally where the shockwave interacts with the notch geometry, enabling precise micron-scale joining while maintaining overall structural integrity. This localized action allows for high manufacturing precision without compromising structural strength.
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 enables efficient and precise joining of dissimilar materials at the micron scale with minimal damage, avoiding thermal alteration of the materials and allowing for high repeatability and low heat input, suitable for applications in microelectronics and biomedical fields.
Implementation Method 1
an ablation layer disposed between the confinement layer and the first component
Implementation Method 2
generating a shockwave in a first component to form a jet of material
Implementation Method 3
form a jet of the first component directed towards a second component and penetrating the second component with the jet
Data Source
AI summary
Joining methods and corresponding structures are disclosed. In some instances, a method for joining two or more components may include generating a shockwave in a first component to form a jet of a material of the first component directed towards a second component. The jet may penetrate the second component to connect the first component with the second component. Articles of pre-joined and joined components are also described.