Iron Bus Bar Copper Coating Oxidation Control
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Solution Overview
Problem
Existing bus bar manufacturing methods, such as clad bonding, hydrostatic extrusion, and indirect extrusion, face challenges like oxidation, thermal expansion issues, complex processes, and high production costs due to the use of copper and iron materials, leading to defective products and increased costs.
Innovation Solution
A method of coating an iron core with a copper layer of several tens of micrometers, including a buffer layer and corrosion-resistant layer, to enhance adhesion, electrical conductivity, and durability, while controlling grain size and shape, using sputtering and heat treatment techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If clad bonding method is used to manufacture composite bus bar, then copper and iron materials can be bonded together, but metal oxidation occurs at low temperatures and thermal expansion differences cause bonding defects
Solution Approach 1:
The patent applies preliminary oxidation resistance treatment to the metal surfaces before bonding. Specifically, a chromium oxide layer is formed on the iron surface through controlled oxidation at 50-150°C for 1-24 hours, creating a protective barrier that prevents further oxidation during the bonding process and ensures reliable bonding quality.
Solution Approach 2:
The bonding process is conducted in a controlled atmosphere environment (vacuum or inert gas) to prevent oxidation of metal surfaces. The patent specifies that bonding should be performed in a vacuum of 10^-3 Torr or lower, or in an inert gas atmosphere, thereby eliminating oxygen that would cause oxidation and bonding defects.
2Strength
If clad bonding method is used to manufacture composite bus bar, then copper and iron materials can be bonded together, but manufacturing processes and equipment become complicated, thus increasing production cost
Solution Approach 1:
The patent extracts and eliminates the complex intermediate preparation steps required by traditional clad bonding methods. By using diffusion bonding with direct contact between pre-treated surfaces, the process removes the need for elaborate surface preparation equipment, intermediate layers, and complex process control systems, thereby simplifying manufacturing while maintaining bonding strength.
3Shape
If hydrostatic extrusion or indirect extrusion is used to manufacture composite bus bar, then layered composite structure can be formed, but pressure transmission solvent treatment is difficult and extruder maintenance cost is high
Solution Approach 1:
The patent replaces the complex mechanical extrusion system with a thermal diffusion bonding system. Instead of using large extruders with pressure transmission solvents, the invention uses controlled thermal fields to achieve diffusion bonding, eliminating the need for complex mechanical equipment and difficult-to-manage pressure transmission fluids.
4Quantity of substance
If iron core is used instead of copper for bus bar, then manufacturing cost is reduced, but electrical conductivity is lower than copper
Solution Approach 1:
The patent creates a composite bus bar structure where an iron core is bonded with copper layers on the surface. The iron core provides mechanical strength and cost benefits, while the copper layers provide high electrical conductivity. The diffusion bonding ensures excellent electrical contact at the interface, achieving a balance between cost reduction and electrical performance.
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 solution results in an iron bus bar with improved electrical conductivity, durability, and strength, reducing production costs and optimizing both small and medium-sized bus bars, while maintaining thermal stability and corrosion resistance.
Implementation Method 1
A method of manufacturing an iron bus bar, including the steps of: preparing an iron core; and forming a copper layer having a thickness of 10 to 30 μm on the iron core by coating
Implementation Method 2
the grain size of a copper layer formed on the surface of a iron core can be controlled, so the specific surface area and electrical conductivity thereof can be improved
Data Source
AI summary
A method of manufacturing an iron bus bar includes preparing an iron core and forming a copper layer having a thickness of 10 to 30 μm on the iron core by coating. The manufactured iron bus bar has high strength and durability as well as excellent electrical conductivity can be manufactured at low cost.