Joined Body With Anchor-Forming Intermediate Layer
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Solution Overview
Problem
Conventional methods for joining a metal layer to a ceramic base material often result in poor adhesion, significant variation in adhesion strength, high costs, and require expensive equipment, making them inefficient and unreliable.
Innovation Solution
A joined body is formed by applying an intermediate layer coating with an anchor forming material that protrudes from the coating, allowing the metal layer to adhere both to the coating and the anchor forming material, thereby enhancing adhesion through an anchor effect, using materials like Al2O3, Si3N4, and SiC, and employing fusing agents with metal salts and oxides to achieve strong and consistent bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sputtering or plating methods are used to join metal layer to ceramic base material, then the joining process can be completed, but the adhesion between metal layer and base material is poor and shows large variation
Solution Approach 1:
An intermediate layer is introduced between the metal layer and ceramic base material. This intermediate layer contains anchor structures that mechanically interlock with both the metal layer and the ceramic substrate, serving as a mediator that improves adhesion. The intermediate layer may include materials such as glass ceramics, binders, or composite materials that are compatible with both the metal and ceramic surfaces.
Solution Approach 2:
The surface of the ceramic base material is pre-treated before metal deposition to enhance adhesion. This may involve roughening the surface, applying a primer or bonding agent, or creating anchor patterns on the ceramic surface beforehand. The metal layer is then deposited onto this pre-prepared surface, ensuring better mechanical interlocking and chemical bonding.
2Reliability
If expensive equipment like sputtering apparatus is used to achieve metal layer deposition, then metal layer can be formed, but the joining cost becomes high
Solution Approach 1:
The patent employs low-cost, easily applicable materials and methods such as screen printing, dip-coating, or spray application of the intermediate layer, followed by simple firing or curing processes. These replace expensive vacuum deposition equipment with conventional, cost-effective manufacturing techniques that achieve comparable or superior adhesion results.
Solution Approach 2:
The invention changes the processing parameters from high-vacuum, high-temperature sputtering conditions to atmospheric pressure, lower temperature firing or curing conditions. This allows the use of standard industrial equipment rather than specialized expensive apparatus, significantly reducing manufacturing costs while maintaining adhesion quality.
3Reliability
If conventional joining methods are used, then metal layer can be deposited on ceramic, but the technical difficulty and expertise required for joining is high
Solution Approach 1:
The intermediate layer is designed to self-adhere to both the ceramic substrate and the metal layer through inherent chemical or mechanical properties. For example, the intermediate layer may contain reactive groups that automatically bond to ceramic surfaces upon firing, or anchor structures that mechanically interlock with deposited metal without requiring additional processing steps. This eliminates the need for operator expertise in controlling complex deposition parameters.
4Reliability
If expensive specialized equipment is used for joining, then joining can be achieved, but the equipment cost becomes high
Solution Approach 1:
The patent replaces complex mechanical vacuum deposition systems with simpler thermal or chemical processing systems. Instead of using sputtering apparatus that require vacuum chambers and high-power RF sources, the invention uses conventional furnaces for firing intermediate layers or simple coating processes that operate at atmospheric pressure, dramatically reducing equipment investment.
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
The solution achieves high and consistent adhesion strength with reduced costs, eliminating the need for expensive equipment, and ensuring reliable bonding for ceramic-based components like heat sinks and LEDs.
Implementation Method 1
the intermediate layer coating is fused to the joint surface of the joining base material
Implementation Method 2
an anchor forming material that forms an anchor for joining the metal layer by an anchor effect
Implementation Method 3
employing fusing agents with metal salts and oxides to achieve strong and consistent bonding
Data Source
AI summary
A joined body of a joining base material and a metal layer which, when the metal layer is joined to the base material, adhesion of the metal layer is high, variation in adhesion is small, and the joining can be performed inexpensively. The metal layer is joined to the joining base material via an intermediate layer coating formed on a joint surface of the base material. The intermediate layer coating is fused to the joint surface of the base material, and an anchor forming material that joins the metal layer by an anchor effect is dispersed and embedded in the intermediate layer coating; the anchor forming material partially protrudes outward from the intermediate layer coating, and is fused to the intermediate layer coating; and the metal layer is joined to a surface of the intermediate layer coating and a surface of the anchor forming material protruding outward from the intermediate layer coating.