Soft-Metal Ceramic Joining Layer for Low-Temperature Bonding
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Solution Overview
Problem
Existing methods for joining ceramic members, such as solid phase and liquid phase joining, often result in deformation and quality deterioration due to high joining temperatures, which require subsequent processing to correct.
Innovation Solution
A joined body is created using a joining layer containing soft metal, which is thermally compressed at a temperature lower than the liquidus of the soft metal to join ceramic members, preventing deformation and quality deterioration, and a manufacturing method involving interposing a soft metal joining material between ceramic members and compressing them at a temperature below the soft metal's liquidus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high joining temperature (1500°C or higher) is used for solid phase or liquid phase joining, then the ceramic members can be joined together, but the ceramic members deform and their surfaces deteriorate in quality
Solution Approach 1:
A joining layer containing soft metal particles is introduced as an intermediary between the ceramic members to be joined. This joining layer enables bonding at lower temperatures (below 1500°C) by providing a eutectic reaction pathway, thereby preventing deformation and surface deterioration of the ceramic members while achieving sufficient joining strength
Solution Approach 2:
The joining temperature is changed from high temperature (1500°C or higher) to lower temperature (below the liquidus of the soft metal, typically below 1500°C). This parameter change is achieved by selecting soft metal particles with appropriate melting characteristics, allowing the ceramic members to be joined without experiencing thermal deformation or surface quality deterioration
2Strength
If high joining temperature (1500°C or higher) is used, then the ceramic members can be joined together, but subsequent processing is required to correct deformation and quality issues
Solution Approach 1:
The soft metal-containing joining layer serves as a mediator that enables low-temperature joining, eliminating the need for subsequent corrective processing steps and simplifying the overall manufacturing process
Solution Approach 2:
By changing the joining temperature parameter to below the liquidus of the soft metal, the invention avoids the need for post-joining correction processes, thereby reducing process complexity while maintaining joining effectiveness
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 allows for a lower joining temperature, preventing deformation and quality issues in ceramic members, eliminating the need for post-joining processing and ensuring a strong, adherent bond while maintaining uniform heating performance in applications like ceramic heaters.
Implementation Method 1
a joining layer which contains soft metal, and joins the first ceramic member and the second ceramic member to each other by being thermally compressed at a joining temperature lower than a liquidus of the soft metal
Data Source
AI summary
A joined body includes a first ceramic member, a second ceramic member, and a joining layer which contains soft metal, and joins the first ceramic member and the second ceramic member to each other by being thermally compressed at a joining temperature lower than a solidus of the soft metal.