Laser-Welded Copper Busbar Contact Section With Local Plating
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Solution Overview
Problem
Manufacturing copper busbars with a contact section is costly due to the need for comprehensive nickel and/or tin plating to prevent corrosion and oxidation, and existing methods do not efficiently utilize material resources.
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 and resistant connection while minimizing the need for full busbar coverage, thus saving material and reducing 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 busbar achieves good corrosion resistance and durability, but the manufacturing cost increases significantly
Solution Approach 1:
The patent applies local quality by selectively plating only specific regions of the busbar (contact sections and connection areas) rather than the entire surface. This localized plating approach maintains corrosion resistance where it is most needed while significantly reducing nickel/tin material consumption and manufacturing costs compared to full-surface plating.
Solution Approach 2:
The patent implements partial action by applying nickel/tin plating only to the extent necessary for functional requirements (contact sections and connection areas) rather than excessive full-coverage plating. This partial plating strategy achieves sufficient corrosion protection for critical areas while minimizing material usage and cost.
2Object-affected harmful factors
If the whole busbar is covered with nickel and/or tin plating, then corrosion protection is ensured, but material consumption and costs increase
Solution Approach 1:
The patent applies local quality by selectively plating only specific regions of the busbar (contact sections and connection areas) rather than the entire surface. This localized plating approach maintains corrosion resistance where it is most needed while significantly reducing nickel/tin material consumption and manufacturing costs compared to full-surface plating.
Solution Approach 2:
The patent implements partial action by applying nickel/tin plating only to the extent necessary for functional requirements (contact sections and connection areas) rather than excessive full-coverage plating. This partial plating strategy achieves sufficient corrosion protection for critical areas while minimizing material usage and cost.
3Loss of substance
If a separate second conductive section is used for connecting the contact section, then nickel/tin covering can be restricted and material saved, but the device structure becomes more complex
Solution Approach 1:
The patent applies segmentation by dividing the busbar into distinct functional sections: a first conductive section for power conduction and a separate second conductive section for contact connections. This segmentation allows independent optimization of each section, enabling selective plating only on the second section where corrosion resistance is critical, thereby saving nickel/tin material while maintaining structural integrity through the unified busbar design.
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
The method achieves a durable and cost-effective connection between copper busbar sections with reduced material usage, maintaining electrical reliability and simplifying the manufacturing process.
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.