Copper-Plated Steel Sheet Protrusions for High-Load Resin Film Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing copper-plated steel sheets face issues with sliding resin films peeling off easily, especially under high load conditions, and there are challenges in maintaining slidability and adhesion to the base material.
Innovation Solution
A copper-plated steel sheet design featuring a copper plated film with a thickness of 1.0 µm or more and 25 or more protrusions of 1.0 µm or more per 1000 µm, providing excellent adhesion to both the base steel sheet and the sliding resin film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a sliding resin film is provided on a conventional copper plated film, then slidability is improved, but the sliding resin film peels off easily under high loads
Solution Approach 1:
The copper plated film is designed with localized protrusions (peaks) having a height of 1.0 µm or more, creating heterogeneous surface topology. These protrusions are distributed at specific densities (25 or more per 1000 µm) to provide anchoring points for the sliding resin film, enhancing adhesion locally where needed while maintaining overall smoothness for slidability.
Solution Approach 2:
The copper plated film surface is pre-formed with protrusions before applying the sliding resin film. This preliminary surface preparation creates mechanical interlocking features that prevent peeling during subsequent sliding operations, addressing the adhesion problem before the resin film is applied.
2Reliability
If the copper plated film thickness is increased to improve adhesion, then sliding resin film peeling resistance improves, but manufacturing cost increases
Solution Approach 1:
Instead of uniformly increasing copper plated film thickness, the invention creates localized protrusions on the film surface. This approach achieves enhanced adhesion through surface topology rather than bulk thickness, reducing material consumption and manufacturing cost while maintaining reliability.
Solution Approach 2:
The invention changes the surface parameter (protrusion height and density) rather than the bulk parameter (film thickness). By controlling protrusion height (≥1.0 µm) and density (≥25 per 1000 µm), adhesion is improved without increasing the overall copper consumption and associated costs.
3Manufacturing precision
If the copper plated film surface is made smooth to reduce irregularities, then surface quality improves, but sliding resin film adhesion deteriorates
Solution Approach 1:
The copper plated film maintains overall smoothness with localized protrusions distributed at controlled densities. The protrusions are confined to specific locations rather than creating widespread roughness, thus preserving surface quality while providing adhesion points for the sliding resin film.
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 design ensures that the sliding resin film remains adhered to the copper plated film, maintaining slidability over a long period even under high loads.
Implementation Method 1
a copper plated film formed on at least one surface of the base steel sheet
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
A copper-plated steel sheet 10 includes a base steel sheet 20 and a copper plated film 30 formed on at least one surface of the base steel sheet 20. The copper plated film 30 continuously covers the base steel sheet 20 with a thickness of 1.0 µm or more in a cross-section parallel to a thickness direction of the copper plated film 30, and has 25 or more protrusions having a height of 1.0 µm or more per 1000 µm.