Al-Cu Composite Corrosion Protection via Acrylate Coating
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Solution Overview
Problem
Aluminium-copper composite semi-finished products exhibit high susceptibility to corrosion, which is not effectively addressed by existing methods.
Innovation Solution
Application of an acrylate-based protective layer containing photoinitiators, adhesion promoters, and fillers to specific areas of the semi-finished product, which is cured under light to form a polymer layer, providing targeted corrosion protection without the need for costly galvanized coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminium-copper composite semi-finished products are produced by plating aluminium sheets and copper sheets, then cost reduction and weight reduction are achieved, but corrosion susceptibility increases significantly
Solution Approach 1:
The patent applies selective plating where only specific areas of the aluminium sheet receive copper coating. The copper plating is concentrated on contact surfaces and areas requiring electrical conductivity, while other areas remain as bare aluminium. This local differentiation allows the product to achieve necessary electrical performance and corrosion resistance at critical points without incurring the full cost of complete copper plating, thus resolving the contradiction between reliability and manufacturing cost.
Solution Approach 2:
The patent creates a composite structure combining copper-plated areas and bare aluminium areas in a single semi-finished product. This composite approach allows different materials to perform their optimal functions: copper provides electrical conductivity and corrosion resistance where needed, while aluminium provides structural integrity and weight reduction where copper is not required. The composite design resolves the contradiction by strategically combining material properties rather than using a single material throughout.
2Reliability
If complete copper plating is applied to aluminium sheets for corrosion protection, then corrosion resistance is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent implements selective copper plating on aluminium sheets, applying copper coating only to specific areas that require electrical conductivity and corrosion protection, such as contact surfaces and connection points. Areas that do not require these properties remain as bare aluminium. This local quality approach dramatically reduces copper material consumption while maintaining necessary performance characteristics, directly resolving the contradiction between reliability and quantity of substance.
Solution Approach 2:
The patent applies partial copper plating rather than complete coverage. The copper coating is applied to the extent necessary to achieve functional requirements (electrical contact and corrosion protection at critical points) without excessive material usage. This partial action principle allows the patent to achieve sufficient corrosion resistance and electrical performance with minimal copper consumption, resolving the contradiction between reliability and material quantity.
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
Significantly reduces corrosion susceptibility while maintaining electrical conductivity and allowing for cost-effective and lightweight production of Al-Cu hybrid materials.
Implementation Method 1
The lacquer is then cured under the effect of light to form acrylate polymer, preferably acrylate copolymer
Implementation Method 2
the adhesion of the lacquer to the aluminium and copper surfaces of the semi-finished product can be improved
Data Source
AI summary
A semi-finished product for electrical engineering is described, which is a composite of an aluminum sheet and a copper sheet. According to this disclosure, the semi-finished product bears an acrylate-based protective layer, which has been applied as a lacquer, which contains at least one photoinitiator and has been cured under the effect of light to form acrylate polymer, preferably acrylate copolymer. This disclosure also relates to an unfinished product produced from such a semi-finished product. A method for producing such a semi-finished product is also described.