Modular Press Plunger Sintering for Uniform Multi-Assembly Pressure
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Solution Overview
Problem
Existing sintering devices require time-consuming and difficult adjustments of press plunger arrangements for connecting components of varying sizes and types, especially when operating in vacuum or negative pressure environments, due to the heavy and slow-cooling metal tools, which complicates precise positional alignment and uniform pressure transmission.
Innovation Solution
A sintering device with adjustable first press plungers placed externally before insertion, allowing for rapid alignment and adjustment, combined with temperature-controlled drive devices and interchangeable plungers, enabling precise and uniform pressure application through individually controlled heating and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal tools and press plungers are used to withstand high pressure forces, then the structural strength is sufficient, but the tools become heavy, slow to cool down, and costly
Solution Approach 1:
The tooling system is divided into modular components: a reusable tool holder and interchangeable press plungers. This segmentation allows the heavy metal tool holder to remain fixed while lighter plunger components are swapped based on specific pressing requirements, reducing overall system weight and cooling time.
Solution Approach 2:
The material properties of press plungers are changed by using different materials optimized for specific applications rather than uniform heavy metal construction. This allows selection of materials with appropriate strength-to-weight ratios for different pressing tasks, reducing tool weight while maintaining necessary pressure resistance.
2Stability of the object's composition
If press plungers are permanently or interchangeably fastened to the upper tool, then the structural stability is maintained, but the adjustment becomes time-consuming and difficult
Solution Approach 1:
The fastening mechanism transitions from permanent to dynamically adjustable. Press plungers are designed with quick-change fastening systems that allow rapid attachment and detachment during operation, enabling dynamic reconfiguration of the tooling setup without time-consuming adjustments while maintaining structural stability during pressing.
Solution Approach 2:
Press plungers are pre-configured with standardized fastening interfaces and positioning features. This preliminary design allows operators to quickly swap and align different plunger configurations without time-consuming adjustments during production, reducing setup time while maintaining pressing stability.
3Strength
If the tools and press plungers are made of metal to withstand high pressure, then the strength is sufficient, but they are slow to cool down
Solution Approach 1:
The tooling system separates the heavy metal tool holder from the lighter plunger components. The plungers can be made of materials with faster thermal conductivity or phase-change materials that cool rapidly, while the structural tool holder provides the necessary strength. This segmentation allows optimized thermal management independent of structural requirements.
Solution Approach 2:
The tooling system uses composite construction combining metal components for strength with materials having superior thermal properties for rapid cooling. This allows simultaneous achievement of high pressure withstand capability and fast cooling rates by selecting appropriate material combinations for different functional requirements.
4Adaptability or versatility
If various assemblies of differing type are processed on a facility, then the versatility is improved, but the adjustment of press plunger arrangement becomes more difficult
Solution Approach 1:
The tool holder is designed with universal features including standardized mounting interfaces, adjustable positioning mechanisms, and modular plunger configurations that can accommodate multiple assembly types. This universality allows the same tooling system to process various assembly configurations without increasing operational complexity.
Solution Approach 2:
The press plunger arrangement incorporates dynamic adjustment mechanisms that allow rapid reconfiguration for different assembly types. These mechanisms enable operators to easily modify plunger positions, numbers, and configurations based on specific assembly requirements, maintaining versatility while simplifying the adjustment process through standardized dynamic interfaces.
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
Facilitates rapid, precise, and uniform pressure sintering of components with varying sizes and types, ensuring consistent temperature control and preventing thermal overload, while reducing tool complexity and operational time.
Implementation Method 1
each of the first press plungers and/or each of the at least one second press plungers is assigned a drive device configured to exert a press force on one of the assemblies by an axial movement of the assigned first press plunger and/or of the assigned second press plunger along an effective direction of the press force
Implementation Method 2
Heat needed for sintering is as a rule transmitted to the component parts via the upper tool and the lower tool, but may also be applied as radiant heat from the lower and/or upper side
Implementation Method 3
pressure sintering for two or more component parts, in particular electronic components and substrates, to be connected to one another in an electrically and/or thermally conductive manner by means of a joining material, wherein the connecting joining material is sintered
Data Source
AI summary
The invention relates to a sintering device (10) and to a sintering method for simultaneously connecting component parts of several electronic assemblies (22) arranged adjacent to one another by means of pressure sintering, with an upper tool (12) and a lower tool (14), comprising several first press plungers (16) assignable to the upper tool (12), and at least one, in particular several second press plungers (18) assigned to the lower tool (14), between which the assemblies (22) are received. Each of the first press plungers (16) and/or each of the at least one second press plungers is (18) assigned a respective drive device (28, 28.1, 28.2) configured to exert a press force on one of the assemblies (22) by an axial movement of the assigned first press plunger (16) and/or of the assigned second press plunger (18) along an effective direction of the press force (P).In accordance with the invention, it is proposed that the first press plungers (16) are placed onto the assemblies (22) before the start of the pressing operation and press the assemblies (22) against the at least one second press plunger (18) during the application of the press force.