Curable Electrical Joint Composition for Low-Resistance Busbar Sealing
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Solution Overview
Problem
Traditional methods for reducing electrical resistance between metal conductors, such as busbars, are inefficient and environmentally challenging, particularly with aluminum busbars, due to natural oxide layers and the use of expensive plating processes, and existing solutions like petroleum grease pose hazards and application limitations.
Innovation Solution
A curable electrical joint composition comprising electrically conductive metals like zinc, tin, and a curable polymer, applied between metal conductors to form a durable seal, reducing resistance and preventing oxidation, with a curing process that can be initiated by heat, light, or pressure, allowing for precise application and efficient joint formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional plating methods (nickel, copper, silver, tin) are used to reduce electrical resistance, then conductivity is improved, but manufacturing cost increases and environmental harm worsens
Solution Approach 1:
The patent replaces expensive, environmentally harmful plating materials with a cost-effective curable composition containing metal particles (such as aluminum, zinc, or stainless steel) suspended in a curable polymer matrix. This composition can be applied as a thin layer and cured in place, providing the necessary electrical conductivity without the high costs and environmental damage associated with traditional plating processes.
Solution Approach 2:
The patent creates a composite material system consisting of conductive metal particles dispersed within a curable polymer matrix. This composite provides both the electrical conductivity needed for joint applications and the adhesive properties of the polymer, eliminating the need for separate plating and bonding operations while reducing material costs and environmental impact.
2Reliability
If petroleum grease is applied to reduce electrical resistance, then conductivity is improved, but safety hazards increase and application versatility worsens
Solution Approach 1:
The patent transforms the physical and chemical parameters of the applied material by using a curable composition that transitions from a liquid or paste state to a solid cured state. This parameter change allows the material to be applied easily in liquid form, then cured to form a stable, non-migrating solid layer that provides consistent electrical conductivity without the safety hazards and application limitations of petroleum-based greases.
Solution Approach 2:
The curable composition replaces petroleum grease with a material that can be applied economically and cured to form a permanent, reliable joint compound. The composition typically uses inexpensive metal particles such as aluminum or zinc combined with a curable polymer, eliminating the need for expensive, hazardous grease formulations while providing superior electrical and mechanical properties.
3Reliability
If grease-like compositions are used to reduce electrical resistance, then conductivity is improved, but application precision worsens due to accumulation on surfaces
Solution Approach 1:
The patent utilizes the parameter change from liquid to solid state through curing to achieve precise application control. The composition can be applied as a controlled liquid or paste layer, then cured to form a stable solid film with consistent thickness and properties. This eliminates the uncontrolled accumulation and migration issues associated with grease-like compositions, enabling precise application to undersides and complex geometries.
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 curable joint composition significantly reduces electrical resistance between metal conductors, providing a durable seal and preventing further oxidation, while allowing for detection of insufficient clamp loads during manufacturing, thus enhancing manufacturing efficiency and safety.
Implementation Method 1
a curing process that can be initiated by heat, light, or pressure
Data Source
AI summary
Provided herein is a. curable electrical joint composition for metallic electrical conductors, and methods of using the same. The curable electrical joint composition includes at least one electrically conductive metal and at least one curable polymer.