Honeycomb Structure Air Gap Formation via Sacrificial Foil
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Solution Overview
Problem
Existing methods for producing honeycomb structures with air gaps face issues such as non-uniform load distribution leading to poor soldering quality, damage during metal foil removal, and lack of automation, making the process time-consuming and non-reproducible, with removed foils being discarded as scrap.
Innovation Solution
A method involving a forming plate with a temperature-resistant web structure that creates a constant air gap during the soldering process, allowing for uniform preloading and automated arrangement of metal foils, which are then interconnected using a soldering process, and the forming plate is removed post-connection to form a honeycomb structure with predefined current paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal foils are wound into the honeycomb structure to create air gaps, then air gaps are formed for electrical insulation, but non-uniform load distribution occurs leading to poor soldering quality
Solution Approach 1:
A sacrificial metal foil is introduced as an intermediary element during the winding process. This sacrificial foil serves as a placeholder that maintains uniform spacing between the adjacently arranged metal foils, ensuring even load distribution during soldering. After the soldering process completes, the sacrificial foil is removed, leaving the desired air gaps for electrical insulation while the solder connections remain intact and of high quality.
2Reliability
If metal foils are removed from the honeycomb structure to produce air gaps, then air gaps are created for electrical insulation, but the honeycomb structure is damaged requiring repair or re-manufacturing
Solution Approach 1:
A sacrificial metal foil is used as a temporary, disposable element during the manufacturing process. This sacrificial foil is specifically designed to be removed after serving its purpose of maintaining uniform spacing during soldering. By using this disposable placeholder, the actual structure remains intact and undamaged, eliminating the need for repair or re-manufacturing while achieving the required air gaps for electrical insulation.
3Reliability
If metal foils are removed from the honeycomb structure to produce air gaps, then air gaps are created, but the process is time-consuming and not reproducible
Solution Approach 1:
The sacrificial metal foil is pre-positioned during the winding process before soldering occurs. This preliminary placement ensures that the correct spacing and air gap configuration are established in advance. The sacrificial foil remains in place throughout the soldering process, guiding the formation of uniform connections. After soldering, the sacrificial foil is simply removed, leaving the finalized air gaps. This preliminary action approach makes the process reproducible and efficient, eliminating time-consuming adjustments or repairs.
Solution Approach 2:
The sacrificial metal foil acts as a temporary mediator that enables automated and reproducible manufacturing. By introducing this intermediary element, the process becomes standardized - the sacrificial foil is consistently placed, consistently maintains spacing during soldering, and is consistently removed. This mediating element allows for reproducible production of air gaps with uniform dimensions, significantly improving productivity and eliminating manual intervention.
4Reliability
If metal foils are removed from the honeycomb structure to produce air gaps, then air gaps are created, but automation of the production process is difficult
Solution Approach 1:
The sacrificial metal foil serves as an intermediary that facilitates automation. During the winding process, the sacrificial foil can be automatically positioned and secured using standard winding equipment. It remains in place as a fixed reference during the soldering process, enabling automated soldering systems to create uniform connections without complex vision systems or adjustment mechanisms. After soldering, the sacrificial foil can be automatically removed using simple extraction tools. This intermediary element transforms a complex, manual process into one that can be fully automated.
5Reliability
If metal foils are removed from the honeycomb structure to produce air gaps, then air gaps are created, but the removed metal foils are disposed of as scrap
Solution Approach 1:
The sacrificial metal foil is designed as a temporary, disposable element used only during the manufacturing process. It is intentionally removed after serving its purpose of maintaining uniform spacing during soldering. While this element is disposed of as scrap, it enables the production of high-quality honeycomb structures with reliable electrical insulation. The use of this sacrificial placeholder minimizes waste of the actual functional metal foils, as they are fully utilized in the final product without needing to be removed or discarded.
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
Ensures uniform preloading and reproducible connection of metal foils, prevents damage to the honeycomb structure, and allows for automation of the production process, enabling the reuse of metal foils by maintaining a consistent air gap and defined current paths.
Implementation Method 1
metal foils arranged adjacent to one another are arranged so as to be electrically insulated by the air gap
Implementation Method 2
interconnection of the at least one metal foil is realized for the permanent formation of the honeycomb structure
Data Source
AI summary
A method for producing a honeycomb structure having at least one at least partially structured metal foil, such that, in subregions of the honeycomb structure, a portion of the at least one metal foil is arranged spaced apart from an adjacently arranged portion of the at least one metal foil so as to be electrically insulated by an air gap therebetween, includes: providing the at least one metal foil; providing a forming plate having a bearing surface and having at least one first web structure extending from the bearing surface in an axial direction, the first web structure extending in a plane parallel to the bearing surface and defining the air gap to be produced in the honeycomb structure; and arranging the at least one metal foil on the bearing surface in the first web structure.