Laser-Welded Shim Foils for Delamination-Resistant Layer Joining
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Solution Overview
Problem
Existing tolerance-compensating layered foils face issues with delamination between layers, especially when used between curved components, due to tension and adhesive limitations, leading to mechanical weaknesses and residue formation during peeling and high-temperature applications.
Innovation Solution
The foils are connected via a welded connection, specifically using laser welding without additional adhesives, allowing for a stable and thin weld seam that enables easy peeling and flexible configuration for curved surfaces, while also allowing for additional gluing over surfaces or edges for enhanced bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive bonding is used to connect foils, then the foils can be joined together to form layered structures, but delamination occurs between layers especially when used between curved components due to tension and adhesive limitations
Solution Approach 1:
The patent replaces adhesive bonding (chemical system) with laser welding (thermal/physical system) to join the foils. This substitution eliminates the delamination issues associated with adhesives under tension and curved geometries, as welding creates a metallurgical bond that maintains integrity under stress and heat.
Solution Approach 2:
The patent changes the bonding mechanism from adhesive-based to weld-based, fundamentally altering the physical and chemical parameters of the joint. Welding creates a fusion bond with different mechanical properties that resist delamination, especially in curved component applications where adhesive bonds fail.
2Ease of operation
If adhesive bonding is used to connect foils, then the foils can be joined together, but residue formation occurs during peeling and high-temperature applications
Solution Approach 1:
The patent replaces adhesive bonding with laser welding, eliminating the organic adhesive material that causes residue formation during peeling and high-temperature exposure. The weld creates a clean metallurgical bond without leaving harmful residues.
Solution Approach 2:
The patent eliminates the need for removable adhesives by using permanent weld bonds. This removes the issue of residue formation entirely, as the weld creates a stable, residue-free connection that maintains integrity under all operating conditions.
3Ease of manufacture
If adhesive bonding is used to connect foils, then the foils can be joined together, but mechanical weaknesses occur due to adhesive limitations
Solution Approach 1:
The patent replaces adhesive bonding with laser welding, substituting a chemically-based joining method with a thermally-based metallurgical process. This creates bonds with superior mechanical strength that can withstand higher loads and stresses while maintaining manufacturing efficiency.
4Device complexity
If multiple foils are glued together at edges using adhesive, then the structure can be assembled, but the connection is weak under tension and curved surface conditions
Solution Approach 1:
The patent replaces edge gluing with laser welding, creating a bond that is significantly stronger under tension and curved surface conditions. The weld penetrates through the foil thickness and creates a fusion bond that maintains strength regardless of geometric complexity.
Solution Approach 2:
The patent transitions from surface-level adhesive bonding to volumetric weld penetration, creating a three-dimensional fusion zone that provides superior mechanical interlocking and bond strength, especially under curved geometries where surface adhesives fail.
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 solution provides a strong, flexible connection that prevents delamination and residue issues, enabling effective tolerance compensation with improved mechanical strength and adaptability for curved surfaces and high-temperature applications.
Implementation Method 1
The foils are connected via a welded connection, specifically using laser welding without additional adhesives
Implementation Method 2
The foils are connected via a welded connection, specifically using laser welding
Data Source
AI summary
The invention generally relates to intermediate layers (shim-type stacked foils/films) as adjusting elements for mechanical structures.