Laser-Laminated Structure Using Melting-Point Layering for Strong Bonding

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Solution Overview

Problem

Existing methods for manufacturing laminated structures require complex processes and a large number of devices, making them inefficient for producing structures with multiple laminated members.

Innovation Solution

A method involving the sequential lamination of three laminates with different melting points, where the middle laminate has a higher melting point than the other two, and laser irradiation is used to melt and join the surface portions of the laminates, allowing them to mesh and form a strong bond.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional methods are used to manufacture laminated structures, then the structure can be formed, but the process becomes complex and requires a large number of devices

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidnumber of devices required

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The invention utilizes changes in melting point parameters of different laminates to enable selective melting. By arranging laminates with different melting points (first laminate: lower melting point, second laminate: highest melting point, third laminate: lower melting point), the process achieves controlled material flow and bonding without requiring complex multi-stage equipment

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces complex mechanical pressing and heating systems with a simplified laser-based approach. Laser light irradiation from the second laminate side selectively melts the first and third laminates, allowing their material to flow into recesses of the second laminate, achieving bonding without complex mechanical device assemblies

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If conventional lamination methods are used, then bonding can be achieved, but the adhesion area and bond strength are limited

Engineering Contradiction:

Improveadhesion between laminatesVSAvoidmanufacturing efficiency

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention creates local quality differences by forming recesses in the second laminate and selectively melting surface portions of the first and third laminates. The melted material flows into these localized recesses, creating strong anchor points that significantly enhance adhesion strength while maintaining manufacturing efficiency

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention exploits phase transitions (melting and solidification) of the laminate materials. By irradiating laser light to melt the surface portions of the first and third laminates, the material becomes fluid and flows into the recesses of the second laminate. Upon cooling and solidification, this creates a mechanical interlock that achieves wide adhesion area and high bond strength

Inventive Principle:

Principle #36Phase transitions

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 allows for the efficient manufacturing of laminated structures with a small number of devices, achieving a wide adhesion area and high adhesion between the laminates, suitable for applications such as heat dissipation devices and electric circuit boards.

Implementation Method 1

irradiating a surface portion of the third laminate on the second laminate side with laser light from the second laminate side to melt the surface portion of the third laminate on the second laminate side

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

melt the surface portion of the third laminate on the second laminate side, and allowing the surface portion that has been melted to enter a recess formed in a surface of the second laminate

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20250031319A1Laminated structure, and method for manufacturing laminated structure

Publication Date: 2025.01.23 PANASONIC HOLDINGS CORP

AI summary

A laminated structure comprising: a first laminate; a second laminate; and a third laminate, wherein the first laminate, the second laminate, and the third laminate being sequentially laminated, melting points of the first laminate, the second laminate, and the third laminate are different from each other, and the melting point of the second laminate is higher than the melting point of any of the first laminate and the third laminate.