Multilayer Brazing Ribbon for Faster Substrate Joining
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Solution Overview
Problem
The inefficiency of brazing operations due to the time-consuming process of forming a brazing alloy layer on substrates and the need for varying brazing alloys based on substrate types, which affects operation efficiency and convenience.
Innovation Solution
A brazing ribbon is manufactured in the form of a sheet with a multilayer structure, comprising a release film, a seed layer, and a brazing alloy layer, including Ag, Cu, and SnAg layers, which can be easily attached to substrates as a strip, using processes like sputtering and plating, and then blanked into a ribbon form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the brazing alloy is directly formed by performing plating on the bonding surface of the substrate to be bonded, then the brazing alloy can be applied to the substrate, but the operation efficiency is low
Solution Approach 1:
The brazing alloy layer is pre-formed on a release film in a separate manufacturing process, creating a ready-to-use brazing ribbon. This preliminary action eliminates the need to perform plating operations during the actual brazing process, thereby improving operation efficiency while maintaining ease of use through simple attachment of the pre-formed ribbon
Solution Approach 2:
The brazing system is divided into separate components: the release film, seed layer, and brazing alloy layer are manufactured as a distinct brazing ribbon product. This segmentation allows the brazing alloy to be prepared independently and applied as a complete unit, improving operational efficiency by eliminating on-site plating operations
2Reliability
If the brazing alloy is formed into a thin film having a multilayer structure, then the brazing alloy can provide enhanced performance, but it takes a lot of time to form the brazing alloy layer on the bonding surface
Solution Approach 1:
The complex multilayer brazing alloy structure is pre-manufactured on the release film, incorporating multiple layers with specific compositions and thicknesses. This preliminary formation of the multilayer structure eliminates the time-consuming process of forming such complex layers during the brazing operation itself, while maintaining the enhanced performance benefits of the multilayer design
Solution Approach 2:
The multilayer brazing alloy is segmented into distinct layers (first brazing alloy layer, second brazing alloy layer, third brazing alloy layer) with different compositions and functions. Each layer is pre-formed with specific properties, allowing the complete multilayer structure to be applied as a unified brazing ribbon, thereby achieving high performance without the time penalty of forming each layer separately during operation
3Reliability
If the type of brazing alloy varies depending on the type of substrate, then the brazing can be optimized for each substrate, but the operation efficiency decreases due to the need to select and apply different alloys
Solution Approach 1:
The release film is designed with universal applicability, allowing different brazing alloy compositions to be manufactured on the same release film substrate. The release film itself serves multiple functions: providing a release surface, enabling easy attachment, and facilitating the application of various brazing alloy types. This universality allows operators to select the appropriate brazing alloy composition for their specific substrate while maintaining efficient operation through the consistent brazing ribbon application process
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 significantly reduces the time required for attaching brazing fillers, enhances operation convenience, and allows for the selection and use of suitable brazing ribbons for different temperatures, eliminating the need for repeated substrate processing.
Implementation Method 1
The step of forming of the seed layer may form the seed layer through a sputtering process
Implementation Method 2
The step of forming the brazing alloy layer may form the brazing alloy layer on the upper surface of the seed layer through a plating process
Data Source
AI summary
The present invention relates to a brazing ribbon and a method for manufacturing same, and comprises a release film, a seed layer formed on an upper surface of the release film, and a brazing alloy layer formed on an upper surface of the seed layer and is manufactured into a ribbon. The present invention is advantageous in that, since a brazing filler is prepared in advance and then attached to a substrate in the form of a strip, time for attaching the brazing filler can be saved, and the convenience of attaching the brazing filler can be improved.