Laser Bonding via Black Coating to Reduce Thermal Damage
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Solution Overview
Problem
Conventional bonding methods using semiconductor lasers often reflect energy, leading to thermal deterioration of resin materials due to high energy requirements, causing issues like burn marks, color change, and deformation.
Innovation Solution
A manufacturing method involving forming perforations with protrusions in the first member, allowing the laser to be blocked and converted into heat within the perforation, thereby reducing the energy needed for bonding and minimizing thermal deterioration of the second member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If semiconductor laser irradiation is applied to bond the first member and second member, then bonding is achieved, but the laser energy is easily reflected making energy conversion to heat ineffective and requiring high laser energy which causes thermal deterioration of the resin material
Solution Approach 1:
A black coating layer is applied to the second member before laser bonding to pre-establish high laser absorption capability. This preliminary action ensures that when laser energy is applied during bonding, the coated surface efficiently absorbs the energy and converts it to heat, preventing reflection losses and avoiding the need for high laser power that would cause thermal deterioration of the resin material.
2Reliability
If high energy laser is used to ensure effective bonding, then bonding reliability is improved, but the resin material suffers from burn marks, color change, and deformation
Solution Approach 1:
The black coating layer, which would normally be considered an additional processing step or modification, is actually the key solution that converts the potential harm of high laser energy into a benefit. By introducing this coating, the system can use lower laser energy levels while still achieving reliable bonding, thereby preventing burn marks, color change, and deformation of the resin material.
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 effectively inhibits thermal deterioration of the second member by ensuring efficient energy conversion, maintaining the integrity of the resin material during the bonding process.
Implementation Method 1
the black coating layer 22 having a function of absorbing the laser 30
Implementation Method 2
the first member nearby the boundary surface is molten, and the first member enters a concave convex part and is fixed
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A bonding structure manufacturing method for manufacturing a bonding structure in which a first member and a second member are bonded is provided with: a step for forming a perforation with an opening in the surface of the first member and forming a protrusion that protrudes into the inner circumferential surface of the perforation; a step for disposing the region of the first member where the perforation is formed adjacent to the second member; and step for filling and curing the second member in the perforation of the first member by irradiating a laser on the region of the first member where the perforation is formed from the second member side.