Clay-like Copper Composition for Sintered Body

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Solution Overview

Problem

Copper clay compositions used for forming sintered copper bodies require pre-baking in an oxidizing atmosphere to combust binders and risk oxide film formation, making the baking process complex and prone to errors.

Innovation Solution

A copper clay composition with a powder mixture containing copper-containing metal powder and copper-containing oxide powder, with an oxygen content of 4-8 mass%, allowing binder combustion in a non-oxidizing atmosphere without pre-baking, and suppressing oxide film generation by maintaining Fe levels below 1000 ppm and using CuO or Cu2O powders within specific ratios.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If copper clay is baked in a non-oxidizing atmosphere without pre-baking, then the baking process becomes simpler and oxide film formation is prevented, but the binder cannot be properly combusted and removed

Engineering Contradiction:

Improvebaking process simplicityVSAvoidbinder removal completeness

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention changes the chemical composition parameters of the powder mixture by incorporating copper oxide powder with specific oxygen content (4-8 mass%). This parameter change enables the binder to be combusted during main baking in non-oxidizing atmosphere without requiring pre-baking, thus resolving the contradiction between process simplicity and binder removal effectiveness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts the previously harmful oxygen (which caused oxide film formation) into a beneficial component by using copper oxide powder as an internal oxygen source for binder combustion. This allows the baking to be performed in non-oxidizing atmosphere, preventing oxide film formation while ensuring complete binder removal

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If pre-baking is performed in oxidizing atmosphere to remove binder, then binder combustion is ensured, but oxide film forms on the copper surface and process complexity increases

Engineering Contradiction:

Improvebinder combustion effectivenessVSAvoidbaking process steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention merges the binder combustion function and oxide film prevention into a single main baking step by using copper oxide powder as an internal oxygen source. This eliminates the need for separate pre-baking and main baking steps, reducing process complexity while maintaining reliability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention converts copper oxide from a potential contaminant into a beneficial oxygen source for binder combustion. This allows the entire baking process to be performed in non-oxidizing atmosphere, preventing oxide film formation while ensuring complete binder removal in one step

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If copper oxide powder is added to provide oxygen for binder combustion, then binder removal is improved, but excess copper oxide may remain in the sintered body

Engineering Contradiction:

Improvebinder removal completenessVSAvoidcopper oxide residue control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention precisely controls the oxygen content parameter of the powder mixture (4-8 mass%) by adjusting the copper oxide powder content. This parameter optimization ensures sufficient oxygen for complete binder combustion while preventing excess copper oxide from remaining in the sintered body, thus resolving the contradiction between binder removal effectiveness and copper oxide residue control

Inventive Principle:

Principle #35Parameter changes

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

Enables straightforward main baking in a non-oxidizing atmosphere, preventing oxide film formation and ensuring high-quality sintered copper bodies with improved sintering properties and mechanical strength.

Implementation Method 1

it is possible to combust and remove the binder even if the copper clay (clay-like composition for forming a sintered copper body) is baked in the non-oxidizing atmosphere

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 2

the amount of oxygen contained in the powder constituent is in a range of from 4 mass % to 8 mass %... it is possible to combust the binder by using this oxygen

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 3

clay-like composition for forming a sintered copper body... sintered copper body obtained from the clay-like composition

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS9321105B2Clay-like composition for forming sintered copper body, powder for clay-like composition for forming sintered copper body, method of manufacturing clay-like composition for forming sintered copper body, sintered copper body, and method of manufacturing sintered copper body

Publication Date: 2016.04.26 MITSUBISHI MATERIALS CORP

AI summary

A clay-like composition for forming a sintered copper body of the present invention includes a powder constituent containing a copper-containing metal powder which contains copper and a copper-containing oxide powder which contains copper; a binder; and water, wherein the amount of oxygen contained in the powder constituent is in a range of from 4 mass % to 8 mass %.