Automatic Powder Carrier Feed for Sintered Power Electronics Joints
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Solution Overview
Problem
Existing joining techniques in power electronics face challenges in achieving high-temperature resistance and stability under changing temperatures, particularly due to the inefficiencies and high manual labor involved in low-temperature joining methods using silver powder.
Innovation Solution
An automated method and system for producing an integral join using a powder carrier with a metal powder layer, where the first joining partner is pressed onto the powder layer, raised with the bonded portion, and arranged between two partners for sintering, utilizing an automatic placement machine with a powder carrier feed and placement tool to ensure consistent contact and sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual feeding of silver powder is used in conventional low-temperature joining methods, then the joining process can be performed, but the outlay and manual labor costs are high
Solution Approach 1:
The system uses automatic powder carrier feed that feeds itself from a magazine without manual intervention. The powder carrier automatically presents the powder layer to the joining position, eliminating the need for manual powder feeding while maintaining continuous operation capability
Solution Approach 2:
The manual mechanical feeding operation is replaced by an automated powder carrier feed mechanism. This mechanical system automatically transports powder carriers from a magazine to the joining position, substituting human labor with automated mechanical movement and positioning
2Productivity
If automatic powder carrier feed is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The powder carrier serves multiple functions: it stores the powder layer, transports it to the joining position, and positions it precisely for the joining operation. This multi-functional component reduces the need for separate systems for powder storage, transport, and positioning, thereby limiting complexity increase
Solution Approach 2:
The powder layer is pre-applied to the powder carrier in advance, and multiple powder carriers are pre-loaded in the magazine. This preliminary preparation eliminates the need for complex real-time powder handling systems during the joining process, simplifying the overall system while maintaining high productivity
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 enhances production throughput, reduces manual errors, and achieves a stable, high-temperature-resistant integral join, improving the reliability and efficiency of joining processes in power electronics.
Implementation Method 1
a sintered join is produced between the first joining partner and the second joining partner by pressing the first joining partner and the second joining partner against one another such that the powder layer portion makes contact both with the first joining partner and the second joining partner. The powder layer portion is sintered as the joining partners are being pressed against one another.
Data Source
AI summary
A powder carrier, to which a powder layer containing a metal powder is applied, is provided by an automatic powder carrier feed. A first joining partner is pressed onto the powder layer located on the powder carrier so as to bond a powder layer portion to the first joining partner. The first joining partner is raised from the powder carrier together with the powder layer portion bonded to the first joining partner, and the powder layer portion bonded to the first joining partner is arranged between the first and second joining partners. A sintered join is produced between the first and second joining partners by pressing the first and second joining partners against one another such that the powder layer portion makes contact with both the first and second joining partners. The powder layer portion is sintered as the joining partners are being pressed against one another.