Laser Welding Copper Strip to Thermally Sprayed Conductive Layer
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Solution Overview
Problem
Existing methods for connecting components, especially those involving copper, often fail to provide reliable and durable connections, particularly in high-voltage applications, and can be susceptible to faults and require filler materials that may lead to embrittlement over time.
Innovation Solution
A method involving a thermally sprayed electrically conductive layer and a copper strip with a thickness of more than 0.1 mm, where a laser beam is used to form a welded connection, ensuring a material-bonded, gas-tight, and moisture-resistant connection with high current-carrying capacity, eliminating the need for filler materials and providing long-term thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional contacting methods (soldering, microresistance welding) are used to connect copper components, then the connection process is simpler, but the reliability and durability of the connection deteriorates, especially in high-voltage applications
Solution Approach 1:
The patent replaces traditional mechanical contacting methods (soldering, microresistance welding) with laser beam welding. This substitution enables reliable material-bonded connections of copper components with thickness >0.1mm, eliminating the limitations of conventional methods while maintaining process feasibility through controlled laser parameters
Solution Approach 2:
The patent changes the key parameter of connection method from thermal/mechanical processes to laser beam processing. By controlling laser power, pulse duration, and beam focus, the process achieves reliable welding of copper strips thicker than 0.1mm, resolving the contradiction between connection reliability and process complexity
2Reliability
If thin copper strips are used to reduce material usage, then the quantity of material decreases, but the current-carrying capacity and reliability deteriorate
Solution Approach 1:
The patent replaces traditional joining methods with laser beam welding, enabling the use of thicker copper strips (>0.1mm) that provide sufficient current-carrying capacity. The laser process creates strong material-bonded connections that maintain electrical conductivity while using optimally thick strips for high-voltage applications
Solution Approach 2:
The patent optimizes the copper strip thickness parameter to be greater than 0.1mm, balancing current-carrying capacity requirements with material usage. Laser welding parameters are adjusted to match this thickness range, achieving reliable connections without excessive material consumption
3Stability of the object's composition
If filler materials are used in traditional welding methods, then the ease of manufacture improves, but the long-term stability deteriorates due to embrittlement
Solution Approach 1:
The patent extracts and eliminates filler materials from the welding process. By using pure copper strip (>0.1mm thickness) with laser beam welding, the process achieves material-bonded connections without any filler materials, preventing embrittlement and ensuring long-term stability while maintaining manufacturing simplicity through direct welding
Solution Approach 2:
The patent replaces filler material-based welding with laser beam welding of pure copper. This substitution eliminates the harmful effects of filler materials on long-term stability while maintaining ease of manufacture through a streamlined, filler-free 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
The method achieves a reliable, durable, and high-current-carrying copper-to-copper connection with reduced susceptibility to faults, maintaining thermal stability and avoiding damage to underlying layers, while ensuring good heat removal and process tolerances.
Implementation Method 1
A laser beam is emitted onto the contact region and a welded connection is thereby formed
Implementation Method 2
the welding of the strip of copper is less susceptible to faults and has greater process tolerances
Implementation Method 3
the strip and/or the layer and/or the connection of the strip to the layer is formed so as to make it possible for a current of in particular at least 15 amperes
Implementation Method 4
providing the first component, which comprises a thermally sprayed electrically conductive layer
Data Source
AI summary
A method for working a first component and a second component comprises the following steps: providing the first component, which comprises a thermally sprayed electrically conductive layer, providing the second component, which has a longitudinally extended strip of copper, which at least in a first region has a thickness transversely to the longitudinal direction of more than 0.1 millimeter, arranging the strip and the layer one on top of the other, so that the first region of the strip and the layer have a contact region in common with one another, emitting a laser beam onto the contact region and forming a welded connection, which connects the strip and the layer to one another.