Busbar Contact Section Laser Welding With Localized Ni/Sn Plating
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Solution Overview
Problem
Existing copper busbars require costly nickel and/or tin plating to prevent corrosion and oxidation, which is inefficient and expensive.
Innovation Solution
A method involving laser welding a second conductive section, covered with nickel and/or tin, to a first copper section, forming a durable connection without covering the entire busbar, thereby reducing material and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the whole busbar is covered with nickel and/or tin plating to prevent corrosion and oxidation, then the durability and corrosion resistance is improved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent applies nickel and/or tin plating only to specific regions of the busbar where corrosion protection is most critical, such as the contact sections and connection areas, rather than covering the entire busbar surface. This localized approach maintains necessary corrosion resistance while significantly reducing material costs and manufacturing complexity.
2Reliability
If the whole busbar is covered with nickel and/or tin plating to prevent corrosion and oxidation, then the durability is improved, but the material usage increases
Solution Approach 1:
The invention implements selective plating only on specific sections of the busbar that require corrosion protection, such as contact areas and connection points, while leaving other sections unplated. This reduces nickel and/or tin material consumption while maintaining sufficient durability for the application.
3Productivity
If laser welding is used to create a bond between copper sections to accelerate manufacturing, then the productivity is improved, but the manufacturing precision may be affected due to heat influence
Solution Approach 1:
The patent optimizes laser welding parameters including power, speed, and focal position to achieve precise welding of copper sections with minimal heat-affected zone. By carefully controlling these parameters, the invention maintains high manufacturing speed while ensuring welding precision and avoiding excessive thermal influence on the 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 creates a durable and resistant connection while minimizing material usage, specifically by applying nickel and/or tin only to the second conductive section, thus reducing costs and maintaining durability.
Implementation Method 1
creating a bond, in particular a laser welding seam, i. e. a laser welding bond, between the first conductive section and the second conductive section, by laser welding
Data Source
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AI summary
A method for forming a busbar (1) having a contact section (20) comprising: - providing a first conductive section (110) made from copper, - providing a second conductive section (120), preferably made from copper, wherein the second conductive section (120) includes the contact section (20) or is connected to the contact section (20) and wherein the second conductive section (120) 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 (110) and the second conductive section (120), by laser welding.