Copper Foil Oxidation Resistance via Amorphous Zinc Layer
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Solution Overview
Problem
Copper foils used in high-temperature applications, such as automotive and vehicle conductors, suffer from inadequate oxidation resistance and appearance degradation due to oxidation, while existing solutions like zinc plating and amorphous alloys either fail to provide sufficient performance or complicate the manufacturing process.
Innovation Solution
A copper foil with a surface-treated layer comprising an amorphous layer of oxygen and a metal with higher oxygen affinity than copper, such as zinc, applied through a simple heat-treatment process, which forms a barrier to inhibit copper oxidation and maintain flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zinc plating is applied to improve oxidation resistance, then oxidation resistance is improved, but the surface appearance deteriorates due to discoloration
Solution Approach 1:
The invention changes the chemical composition parameters by controlling zinc content to 5-30 mass% and adding specific alloying elements (Al, Si, Ti, Mg, Mn, Fe, Ni, Pd, Pt, Au, Ag) in controlled amounts. This parameter optimization allows the surface layer to maintain copper-like appearance while achieving excellent oxidation resistance through the controlled alloy composition and amorphous structure formation during heat treatment.
2Reliability
If nickel plating is applied to improve oxidation resistance, then oxidation resistance is improved, but flexibility decreases and handling properties worsen
Solution Approach 1:
The invention optimizes the thickness parameter of the surface-treated layer to 1-100 μm, which is sufficient to provide oxidation resistance but thin enough to maintain flexibility. The controlled alloy composition and amorphous structure further enable the layer to provide protection while preserving the underlying copper foil's flexibility and handling properties.
Solution Approach 2:
The invention creates a composite structure consisting of the copper-based base material and the surface-treated layer containing copper, zinc, and alloying elements. This composite structure combines the oxidation resistance of the surface layer with the flexibility of the copper base material, achieving both protection and ease of operation.
3Reliability
If amorphous alloy plating is applied to improve oxidation resistance, then oxidation resistance is improved, but the manufacturing process becomes complicated
Solution Approach 1:
The invention performs preliminary alloying by incorporating zinc and other elements during the copper foil manufacturing process itself, rather than requiring separate complex amorphous alloy plating steps. The base copper foil is pre-composed with the necessary alloying elements, simplifying the overall manufacturing process while still achieving the desired amorphous structure and oxidation resistance through subsequent heat treatment.
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 copper foil exhibits excellent oxidation resistance, maintains appearance, and retains good handling properties, even at high temperatures, without the need for complex manufacturing processes or thick nickel plating.
Implementation Method 1
a surface-treated layer that is provided on the copper-based metal sheet and comprises an amorphous layer comprising oxygen and a metal with a higher oxygen affinity than a copper
Implementation Method 2
heat-treating the formed layer at a temperature of not less than 30° C. and not more than 300° C. for not less than 5 seconds and not more than 60 minutes
Data Source
AI summary
A copper foil includes a copper-based metal sheet including mainly a copper, and a surface-treated layer that is provided on the copper-based metal sheet and includes an amorphous layer including oxygen and a metal with a higher oxygen affinity than a copper. A total thickness of the copper-based metal sheet and the surface-treated layer is less than 0.55 mm.