Co-Sintered Transformer Coating for Atmospheric Oxygen Processing
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Solution Overview
Problem
Existing transformer sintering methods require a controlled oxygen environment with less than 15% oxygen content, necessitating an additional step to reduce oxygen levels, which is inconvenient and inefficient.
Innovation Solution
A method for co-sintering transformers that involves applying a nickel or precious metal coating to a copper conductor strip, assembling it with an iron core, pressing them into a mold with iron powder, and sintering in a standard atmospheric environment with 21% oxygen content at 600-900°C for 0.5-3 hours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sintering is conducted in a controlled oxygen environment with less than 15% oxygen content, then oxidation resistance is improved, but process complexity increases due to additional oxygen control steps
Solution Approach 1:
A nickel or precious metal coating layer is applied to the copper conductor strip as an intermediary protective barrier. This coating prevents direct oxidation of the copper during sintering in atmospheric conditions, eliminating the need for complex oxygen control systems while maintaining excellent oxidation resistance
Solution Approach 2:
The invention changes the surface properties of the copper conductor by applying a protective coating, which fundamentally alters its chemical reactivity. This allows the sintering process to proceed in atmospheric oxygen conditions (21% oxygen) without oxidation damage, transforming a process that required controlled oxygen parameters into one that uses standard atmospheric conditions
2Reliability
If sintering is conducted in a controlled oxygen environment, then oxidation resistance is improved, but manufacturing time increases due to additional preparation steps
Solution Approach 1:
The protective nickel or precious metal coating is applied to the copper conductor strip before assembly and sintering. This preliminary protective action ensures that the copper is already shielded from oxidation before entering the sintering process, eliminating the need for time-consuming oxygen control preparations and atmosphere management during sintering
Solution Approach 2:
The invention extracts the oxygen control requirement from the sintering process by providing oxidation protection through coating. This separates the oxidation protection function from the atmospheric environment control, allowing the sintering to proceed in simple atmospheric conditions without time-consuming oxygen level adjustments
3Reliability
If a nickel or precious metal coating is applied to the copper conductor strip, then oxidation resistance and conductivity are improved, but manufacturing complexity increases
Solution Approach 1:
Instead of requiring complex atmospheric control throughout the entire sintering process, the invention applies localized protective coating only to the copper conductor strip surface. This targeted approach provides oxidation protection exactly where needed (at the copper surface) without requiring system-wide process complexity
Solution Approach 2:
The invention creates a composite structure by combining copper conductor material with a protective nickel or precious metal coating layer. This composite material structure integrates both electrical conductivity (from copper) and oxidation resistance (from the coating) into a single component, simplifying the overall manufacturing process
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 method allows for sintering in a standard atmospheric environment without additional oxygen control, resulting in improved oxidation resistance and conductivity of the transformer, with superior performance compared to prior art.
Implementation Method 1
the oxidation resistance and conductivity with a second metal layer of precious metal coating are superior
Implementation Method 2
sintering the pressed transformer from the pressing step in an atmospheric environment with an oxygen content of 21% at a temperature 600 ̃900° C. for a duration 0.5 ̃3 hours
Implementation Method 3
placing the assembled copper conductor strip and the iron core from the assembly step into a mold, filling iron power into the mold, and producing an integrally formed transformer by pressing
Data Source
AI summary
The method for co-sintering transformer includes the following steps: a preparation step providing a copper conductor strip and an iron core; a coating step applying a layer of nickel coating, or a layer of precious metal coating, or both on the copper conductor strip from the preparation step; an assembly step putting the copper conductor strip from the coating step and the iron core from the preparation step together to form a transformer; a pressing step pressing the assembled copper conductor strip and the iron core from the assembly step, together with iron power, in a mold into an integrally formed transformer; and a sintering step sintering the pressed transformer from the pressing step in an atmospheric environment. The present method is able to conduct sintering directly under the atmospheric environment without reducing oxygen content. Iron powder also exhibits improved characteristics after sintering in the atmospheric environment.