Magnetically Controlled Amalgamation Preform for Flux-Free Bonding

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Solution Overview

Problem

Classical bonding and joining techniques, such as soldering and brazing, require thermal energy and flux to remove oxides and contaminants, which can be detrimental to the formation of strong joints and are environmentally and operationally challenging.

Innovation Solution

An amalgamation preform comprising a base metal with dispersed non-reactive and reactive particles, where the reactive particles have a core-shell structure and are magnetically controlled to prevent reactions at room temperature, allowing for controlled dispersion and bonding without the need for thermal energy or flux.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermal energy and flux are used in classical bonding techniques, then oxide removal and contaminant elimination are achieved, but environmental harm and operational complexity increase

Engineering Contradiction:

Improvebond strengthVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention extracts and eliminates the flux component from the bonding process. By using a composite preform consisting of reactive metal particles dispersed in a base metal matrix, the system achieves oxide removal through controlled reaction at the particle level without requiring external flux application, thereby reducing environmental harm while maintaining bond reliability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The reactive metal particles serve as intermediaries that mediate between the base metal and the oxide/contaminant layers. These particles react preferentially with oxides and contaminants, converting harmful substances into removable reaction products without requiring external flux, thus resolving the contradiction between effective cleaning and environmental protection

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If thermal energy is applied to melt filler material, then bonding is achieved, but energy consumption and process complexity increase

Engineering Contradiction:

Improvejoint formationVSAvoidthermal energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The bonding capability is prepared in advance during preform manufacturing. The reactive metal particles are pre-dispersed in the base metal matrix with controlled composition and morphology, so that when the preform is applied, bonding occurs through controlled reaction rather than requiring extensive thermal processing, thereby reducing energy consumption while ensuring reliable joint formation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention changes the bonding mechanism from thermal melting to chemical reaction. By controlling the reactivity parameters of the metal particles and their composition, bonding occurs through exothermic reactions at lower temperatures, significantly reducing thermal energy consumption compared to conventional melting-based processes

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If reactive particles are dispersed in base metal at room temperature, then preform stability is maintained, but particle aggregation may occur

Engineering Contradiction:

Improvepreform shelf lifeVSAvoidparticle distribution

Core Design Contradiction:

Stability of the object's compositionVSShape

Solution Approach 1:

The invention creates a composite material system where reactive metal particles are dispersed in a base metal matrix. The matrix provides a stabilizing environment that prevents particle aggregation while maintaining room temperature stability. The composite structure ensures uniform particle distribution and prevents segregation during storage, resolving the contradiction between stability and distribution

Inventive Principle:

Principle #40Composite materials

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 enables the formation of strong bonds without inducing reactions at room temperature, extending the shelf life of the preform and allowing for efficient bonding with improved mechanical and thermal properties, reducing environmental impact and operational complexity.

Implementation Method 1

non-reactive magnetic particles, responsive to a magnetic field for controllably dispersing the plurality of types of solid particles in the base metal

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 2

reactive particles, reactable with the base metal under the magnetic field

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS11826858B2Amalgamation preform

Publication Date: 2023.11.28 MESOGLUE INC

AI summary

An amalgamation preform is provided. The amalgamation preform includes a base metal, and a plurality of types of solid particles dispersed in the base metal, the base metal including one of a liquid base metal and a solid base metal. The plurality of types of solid particles at least includes: non-reactive magnetic particles, responsive to a magnetic field for controllably dispersing the plurality of types of solid particles in the base metal, and reactive particles, reactable with the base metal under the magnetic field.