CONTROLLABLY-FORMED BRAZING STRUCTURES AND RELATED COMPOSITIONS AND METHODS

• US 20150110548A1
• Filed: 10/22/2014
• Published: 04/23/2015
• Est. Priority Date: 10/23/2013
• Status: Active Grant

• Current Assignee: Concept Group, LLC
• Original Assignee: Aarne H. Reid
• Inventors: Reid, Aarne H.
• Granted Patent: US 9,676,064 B2
• Time in Patent Office: Days
• US Class Current: 403/272
• CPC Class Codes: B23K 1/0008 specially adapted for particular articles or work
• CPC Class Codes: B23K 1/0056 soldering by means of beams, e.g. lasers, E.B.
• CPC Class Codes: B23K 1/203 Fluxing, i.e. applying flux onto surfaces
• CPC Class Codes: B23K 35/0222 for use in soldering, brazing B23K35/0205 takes precedence
• CPC Class Codes: B23K 35/0244 Powders, particles or spheres; Preforms made therefrom
• CPC Class Codes: B23K 35/025 Pastes, creams, slurries
• CPC Class Codes: B23K 35/282 Zn as the principal constituent
• CPC Class Codes: B23K 35/286 Al as the principal constituent
• CPC Class Codes: B23K 35/3006 Ag as the principal constituent
• CPC Class Codes: B23K 35/3013 Au as the principal constituent
• CPC Class Codes: B23K 35/302 Cu as the principal constituent
• CPC Class Codes: B23K 35/3033 Ni as the principal constituent
• CPC Class Codes: B23K 35/3613 Polymers, e.g. resins
• CPC Class Codes: B23K 35/362 Selection of compositions of fluxes B23K35/365, B23K35/368 take precedence
• CPC Class Codes: F16B 5/08 by means of welds or the like welding B23K

Abstract

The present disclosure provides compositions and methods for forming three-dimensional structures atop substrates. These structures may be formed and processed so as to braze together two substrates. The structures may be controllably formed in three dimensions so as to accommodate virtually any substrate geometry or configuration. The structures may also be disposed so as to maintain spacing between two surfaces.

Claims

1. A composition, comprising:

a binder and a brazing material.

2. The composition of claim 1, wherein the binder comprises a polymer.

3. The composition of claim 1, further comprising an aerogel

4. The composition of claim 1, wherein the brazing material comprises a metal.

5. The composition of claim 2, wherein the polymer comprises polyester, polyurethane, polyamide, polyester, epoxy, acrylic, PEEK, or any combination thereof.

6. The composition of claim 4, wherein the metal comprises aluminum, silicon, copper, silver, zinc, gold, nickel, or any combination thereof.

7. The composition of claim 1, wherein at least one of the binder and brazing material are present as a population of particulates.

8. The composition of claim 7, wherein the population of particulates comprises one or more particles having a cross-sectional dimension of less than about 50 microns.

9. The composition of claim 2, wherein the aerogel comprises a carbon aerogel, a silica aerogel, an alumina aerogel, SEAgel, chalcogel, or any combination thereof.

10. A method, comprising:

applying a composition comprising at least two of a binder, a brazing material, and an aerogel; and

solidifying at least a portion of the composition so as to form a structure.

11. The method of claim 10, wherein the structure is disposed so as to contact first and second substrates.

12. The method of claim 11, wherein the substrates are tubes arranged in a concentric manner.

13. The method of claim 11, wherein the first and second substrates are essentially parallel to one another.

14. The method of claim 10, wherein the first and second substrates are separated by a varying distance.

15. The method of claim 11, wherein the structure is disposed so as to seal a gap between the first and second substrates.

16. The method of claim 10, wherein the solidifying is effected by laser energy.

17. The method of claim 10, wherein the structure defines a cross-sectional dimension of between about 0.01 microns and about 100,000 microns.

18. The method of claim 17, wherein the structure defines a cross-sectional dimension of between about 1 microns and about 100 microns.

19. The method of claim 11, wherein the structure is disposed so as to define a region of reduced pressure.

20. The method of claim 16, wherein the solidifying is effected contemporaneously with the applying.

21. A composition, comprising:

a binder and an aerogel.

22. The composition of claim 21, wherein the binder comprises a polymer.

23. The composition of claim 22, wherein the polymer comprises polyester, polyurethane, polyester, epoxy, acrylic, or any combination thereof.

24. The composition of claim 21, wherein at least one of the binder and aerogel are present as a population of particulates.

25. The composition of claim 24, wherein the population of particulates comprises one or more particles having a cross-sectional dimension of less than about 50 microns.

26. The composition of claim 21, wherein the aerogel is characterized as being a carbon aerogel, a silica aerogel, an alumina aerogel, SEAgel, chalcogel, or any combination thereof.

27. A method, comprising:

applying a composition comprising at least two of a binder, a brazing material, and an aerogel to a first surface; and

solidifying at least a portion of the composition so as to form a structure.

28. The method of claim 27, wherein the surface is a surface of a first tube.

29. The method of claim 27, further comprising positioning a second surface relative to the first surface such that a spacing between the first and second surfaces is defined at least in part by the structure.

30. The method of claim 29, wherein the first surface is characterized as the outer surface of a first tube and wherein the second surface is characterized as the inner surface of a second tube.

31. The method of claim 29, wherein spacing between the first and second surfaces varies.

32. The method of claim 27, wherein the solidifying is effected by laser energy.

33. The method of claim 27, wherein the structure defines a cross-sectional dimension of between about 0.01 microns and about 100,000 microns.

34. The method of claim 33, wherein the structure defines a cross-sectional dimension of between about 1 microns and about 100 microns.

35. The method of claim 27, wherein the solidifying is effected contemporaneously with the applying.

36. A workpiece, comprising:

a first structure and a second structure separated by a distance, the distance being at least partially occupied by a composition comprising a binder, a brazing material, and an aerogel.

37. The workpiece of claim 36, wherein the composition maintains the distance between the first and second structures.