Laser-Welded Aluminum Busbar With Selective Plating
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Solution Overview
Problem
The existing methods for manufacturing busbars are cost-intensive and inefficient, particularly in providing durable connections between conductive sections and contact elements made from different materials, and require extensive nickel and/or tin plating for corrosion protection.
Innovation Solution
A method involving a first conductive section made from aluminum and a second conductive section, partially covered with nickel and/or tin, connected via laser welding, allowing for a durable and resistant bond between the sections and enabling the use of a contact element made from a different material, such as copper, while reducing the need for extensive plating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the whole busbar is covered with nickel and/or tin plating for corrosion protection, then the durability and corrosion resistance are improved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent applies selective plating only to specific regions of the busbar where contact elements are attached, rather than plating the entire busbar surface. This localized approach maintains corrosion protection at critical interfaces while significantly reducing material consumption and manufacturing costs.
Solution Approach 2:
The invention uses partial plating action - applying nickel and/or tin coating only to the extent necessary for protecting contact regions, rather than complete coverage. This partial action achieves sufficient corrosion protection for reliable operation while avoiding the excessive cost of full-surface plating.
2Adaptability or versatility
If contact elements made from different materials (e.g., copper) are connected to aluminum conductive sections, then the adaptability to specific applications is improved, but the connection reliability deteriorates due to material incompatibility
Solution Approach 1:
The patent introduces nickel and/or tin plating as an intermediary layer between dissimilar materials (e.g., copper contact elements and aluminum conductive sections). This intermediate coating layer prevents direct galvanic contact between incompatible materials, eliminating galvanic corrosion and ensuring reliable long-term connections while maintaining material versatility.
Solution Approach 2:
The invention creates a composite structure consisting of multiple materials (aluminum, copper, nickel, tin) arranged in specific configurations. The composite approach allows each material to contribute its beneficial properties while the overall structure achieves compatibility and reliability through proper material pairing and interface design.
3Ease of manufacture
If a separate second conductive section is used to connect the contact element to the first conductive section, then the ease of manufacture is improved by simplifying plating processes, but the device complexity increases
Solution Approach 1:
The patent divides the busbar into separate conductive sections (first and second conductive sections) that can be manufactured and plated independently. This segmentation allows each section to receive appropriate plating treatment in isolation, simplifying the plating process setup and execution, while the sections are later assembled to form the complete busbar structure.
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 results in a cost-effective and durable busbar connection with improved electrical and mechanical properties, allowing for the use of aluminum as the main component and accommodating different material contact elements, while minimizing material usage and manufacturing costs.
Implementation Method 1
creating a laser welding bond, in particular a laser welding seam, between the first conductive section and the second conductive section, by laser welding
Implementation Method 2
the second conductive section, being covered with nickel and/or tin
Implementation Method 3
creating a bond between the second conductive section and the contact element, preferably by soldering
Data Source
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AI summary
A method for forming a busbar (1) having a contact element (20) comprising: - providing a first conductive section (11) made from aluminum, - providing a second conductive section (12) made from aluminum, wherein the second conductive section (12) is connected to the contact element (20), the contact element (20) being made from a material different from aluminum, preferably from copper, and wherein the second conductive section (12) is at least partially covered with nickel and/or tin and - creating a laser welding bond, in particular a laser welding seam (10), between the first conductive section (11) and the second conductive section (12), by laser welding and - creating a bond between the second conductive section and the contact element, preferably by soldering.