Wicking Material Voids in Bonded Layered Structures
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Solution Overview
Problem
Voids and their contents in bonded layered structures can cause instability and damage in low-pressure or vacuum environments, such as space, leading to reduced performance in electrical, thermal, and mechanical contacts due to the expansion of trapped gases, which are difficult to detect and repair during manufacturing.
Innovation Solution
Incorporating a wicking material with a venting path in the bonding material layer that is resistant to bonding with other layers, allowing trapped gases to be evacuated through the wicking material's pathways, which can be designed as strands, meshes, or tubular structures that dissolve or sublimate during curing, facilitating the removal of gases before the structure is fully bonded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a bonding material layer is applied to bond substrate layers, then bonding strength is improved, but voids containing trapped gas are introduced which cause instability in vacuum environments
Solution Approach 1:
A wicking material is introduced as an intermediary component within the bonding material layer. This wicking material creates capillary channels that serve as pathways for trapped gas to escape during vacuum processing, thereby resolving the contradiction between maintaining bonding strength and ensuring vacuum stability.
Solution Approach 2:
The wicking material possesses a porous or fibrous structure that enables capillary action. This porous structure allows the material to absorb and transport trapped gas through capillary channels while maintaining the overall integrity and bonding strength of the layered structure.
2Reliability
If the wicking material is made resistant to bonding, then gas evacuation pathways are maintained, but bonding adhesion in the bonding material layer is reduced
Solution Approach 1:
The wicking material exhibits local quality differentiation: it is hydrophobic or chemically resistant to bonding material at its surface to maintain open capillary channels for gas evacuation, while allowing sufficient bonding adhesion in the bulk regions. This localized property variation resolves the contradiction between gas evacuation capability and bonding adhesion.
3Measurement precision
If voids are detected during manufacturing, then quality control is improved, but repair becomes difficult after bonding material cures
Solution Approach 1:
The wicking material is incorporated into the bonding layer before curing occurs. This preliminary action creates built-in capillary channels that enable gas evacuation during subsequent vacuum processing, eliminating the need for difficult post-curing repairs and allowing quality control to focus on detection rather than correction.
4Stress or pressure
If trapped gas expands in vacuum environment, then pressure equalization is achieved, but layered structure is damaged
Solution Approach 1:
The wicking material provides pathways to extract or remove trapped gas from within the layered structure before vacuum processing. By taking out the gas through capillary channels during bonding or initial vacuum exposure, the subsequent expansion that would cause structural damage is prevented, thus resolving the contradiction between pressure equalization and structural integrity.
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
The solution effectively eliminates trapped gases from the layered structure, enhancing the durability and performance of components in low-pressure environments by establishing a natural venting path that prevents gas expansion and improves bonding adhesion, ensuring reliable operation in space and vacuum conditions.
Implementation Method 1
A wicking material is disposed in the bonding material layer, with the wicking material having a wicking material outer surface... the wicking material is resistant to bonding with one or both of the bonding material layer and the surface material layer... the contents in the voids in the bonding material (e.g., gaseous material) are evacuated from the voids in the bonding material, and eliminated from the layered structure via the venting path
Data Source
AI summary
Methods, apparatuses, and systems are disclosed for manufacturing a structure having layers that may operate in low pressure or vacuum environments. More particularly, methods, apparatuses, and systems are disclosed for minimizing the effects of voids by eliminating their contents in layers of bonded structures. In some implementations, a method for improving bonding within a layered structure comprises applying a bonding material layer to a substrate layer; disposing a wicking material in the bonding material layer, said wicking material having an outer surface; applying a surface material layer to the bonding material layer to form a layered structure; and curing the layered structure.