Laser-Textured Copper Conductor Surface for Low Contact Resistance
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Solution Overview
Problem
Existing electrical conductors in equipment face challenges in controlling contact resistance, which is intrinsically difficult to determine and manage, leading to potential excessive heating and unreliable connections, necessitating additional coatings like tin, silver, gold, or nickel, which are costly and complex.
Innovation Solution
A method involving laser stripping and texturing of bare copper-based electrical conductors using near-infrared pulsed laser radiation to create a network of craters, reducing contact resistance without additional coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional coatings like tin, silver, gold, or nickel are applied to reduce contact resistance, then contact resistance is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The patent removes the additional coating layer entirely and instead extracts/creates a textured surface pattern directly on the base metal surface through laser processing, eliminating the need for separate coating materials and processes while achieving low contact resistance
Solution Approach 2:
The patent replaces the mechanical/chemical coating deposition process with a laser-based surface texturing process, using optical energy to create the functional surface pattern directly on the conductor surface
2Reliability
If additional coatings are applied to reduce contact resistance, then contact resistance is reduced, but manufacturing cost increases
Solution Approach 1:
The patent uses the base metal surface itself as the functional element, eliminating the need for expensive additional coating materials (tin, silver, gold, nickel) and relying on a cost-effective laser processing method
Solution Approach 2:
The patent changes the surface parameters of the base metal through laser texturing, creating a functional surface pattern that achieves low contact resistance without requiring material composition changes or additional coating layers
3Ease of manufacture
If the surface of the conductor is left bare, then manufacturing is simple, but contact resistance is high and connections are unreliable
Solution Approach 1:
The patent applies surface texturing only to specific contact areas of the conductor, maintaining the simplicity of using bare metal overall while creating localized functional patterns where electrical contact occurs, achieving low contact resistance without complex overall manufacturing
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 method effectively reduces contact resistance, ensuring reliable electrical connections and compliance with normative heating tests, while eliminating the need for additional coatings, thus being simple, economical, and efficient.
Implementation Method 1
stripping and texturizing at least a portion of the bare electrical conductor using a laser device emitting radiation comprising a wavelength of between approximately 700 nm and approximately 1600 nm
Implementation Method 2
emitting radiation comprising a wavelength of between approximately 700 nm and approximately 1600 nm
Data Source
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AI summary
The invention relates to a method for manufacturing an electrical conductor intended to equip electrical equipment, comprising the steps of providing (101) a bare electrical conductor made from copper and of stripping and texturizing (103) at least a portion of the bare electrical conductor using a laser device emitting radiation comprising a wavelength of between approximately 700 nm and approximately 1600 nm.