Resilient Washer Locking for Silicon-to-Metal Assembly
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Solution Overview
Problem
Current assembly methods for silicon-based parts, which require fine bonding and are expensive, struggle to securely join parts with restricted plastic domains, such as silicon, with metal components without causing destructive forces.
Innovation Solution
An assembly system using a single elastic locking element, like a washer, that radially clamps a metal axis and applies an axial elastic force to a bearing surface, securing the assembly without glue, using materials like copper or brass with high resistance to relaxation, ensuring no breakage of silicon-based parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If bonding is used to join silicon-based parts with metal components, then assembly precision is improved, but manufacturing cost increases and process complexity increases
Solution Approach 1:
The patent replaces the chemical bonding process with a mechanical locking system. A locking element with radial arms engages with slots in the silicon-based part and corresponds to a bearing surface on the metal component, creating a purely mechanical connection that eliminates the need for adhesive bonding processes while maintaining assembly precision.
Solution Approach 2:
The locking element serves as an intermediary component between the silicon-based part and the metal component. It mediates the connection by providing radial arms that engage with the part's slots and a bearing surface that contacts the metal component, enabling secure joining without direct bonding between the dissimilar materials.
2Manufacturing precision
If bonding is used to join silicon-based parts with metal components, then assembly precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces the chemical bonding process with a mechanical locking system. A locking element with radial arms engages with slots in the silicon-based part and corresponds to a bearing surface on the metal component, creating a purely mechanical connection that eliminates the need for adhesive bonding processes while maintaining assembly precision.
3Strength
If axial force is applied to secure silicon-based parts, then assembly strength is improved, but the part may break due to lack of plastic domain
Solution Approach 1:
The locking element distributes the securing force locally at the bearing surface contact point on the metal component, rather than applying distributed axial force across the brittle silicon-based part. The radial arms engage with slots to provide localized mechanical interlocking, concentrating the strength-providing function where the ductile metal component can accommodate the forces without breaking.
Solution Approach 2:
The locking element serves as an intermediary component between the silicon-based part and the metal component. It mediates the connection by providing radial arms that engage with the part's slots and a bearing surface that contacts the metal component, enabling secure joining without direct bonding between the dissimilar materials.
4Strength
If a locking element with large surface area is used, then assembly strength is improved, but the locking element may exert excessive force on the bearing surface causing part breakage
Solution Approach 1:
The locking element distributes the securing force locally at the bearing surface contact point on the metal component, rather than applying distributed axial force across the brittle silicon-based part. The radial arms engage with slots to provide localized mechanical interlocking, concentrating the strength-providing function where the ductile metal component can accommodate the forces without breaking.
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 simplifies the assembly of parts with little or no plastic domain, ensuring secure attachment without relative displacement, avoiding the need for glue or additional locking mechanisms, and maintaining structural integrity over time.
Implementation Method 1
a single locking element in a third material arranged to elastically attach the part between the bearing surface of said member and said single locking element
Implementation Method 2
The single locking element is a washer whose inner wall radially clamps the axis of the component
Implementation Method 3
the third material comprises a metal or metallic alloy whose resistance to relaxation, after 10,000 hours at a temperature of 70°C, is at least equal to 50% of the applied force
Data Source
Figure 1~9
Figure 3~8
Figure 10
AI summary
The invention relates to an assembly system comprising a component made of at least one first material having an axis and a bearing surface, the axis of the component being received in the opening of a part made of a second material having little or no plasticity. According to the invention, the assembly system comprises a locking element made of a third material arranged to elastically attach the part between the bearing surface of said component and the locking element, and in that the locking element is a washer whose inner wall radially clamps the axis of said component and whose peripheral part exerts an axial and elastic force directly above the bearing surface of said component in order to secure the assembly of the component, the part, and the locking element.