Roughened Nickel-Plated Metal for Multi-Directional Shear Durability
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Solution Overview
Problem
Existing nickel-plated metal sheets face issues with shear durability when subjected to loads from multiple directions during industrial manufacturing processes, such as rolling and stacking with other materials, leading to potential breakage of protrusions and reduced adhesion.
Innovation Solution
A nickel-plated metal material with a roughened nickel layer characterized by specific surface texture parameters, including a root mean square height (Rq) of 0.29 µm to 0.90 µm, maximum height (Sz) of 3.5 µm to 10.0 µm, Developed Interfacial Area Ratio (Sdr) of 16% to 75%, and a relative load length ratio (Rmr) of 33% to 95%, along with optional intermediate layers and coating metals to enhance durability and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a roughened nickel layer is formed to improve adhesion with another member, then adhesion performance is improved, but the layer becomes vulnerable to breakage under loads from multiple directions during manufacturing
Solution Approach 1:
The invention changes the surface texture parameters of the nickel layer by controlling the root mean square height (Rq) to 0.29-0.90 μm and maximum height (Sz) to 3.5-10.0 μm. This parameter optimization allows the roughened layer to maintain both adhesion performance and resistance to breakage under multi-directional loads during manufacturing processes
Solution Approach 2:
The invention creates a composite structure by forming an intermediate layer between the base material and the roughened nickel layer. This intermediate layer acts as a transition zone that enhances the overall durability and load-bearing capacity of the plated structure while maintaining the roughened surface characteristics needed for adhesion
2Strength
If the roughened nickel layer is made more durable to withstand manufacturing loads, then shear durability is improved, but adhesion with another member may be compromised
Solution Approach 1:
By precisely controlling surface texture parameters (Rq: 0.29-0.90 μm, Sz: 3.5-10.0 μm), the invention achieves an optimal balance where the roughened layer is sufficiently durable to withstand manufacturing loads while maintaining the necessary surface characteristics for effective adhesion with another member
Solution Approach 2:
The intermediate layer serves as a mediator between the base material and the roughened nickel layer, distributing mechanical stresses and enhancing overall structural integrity. This intermediary layer allows the roughened surface to maintain its adhesion properties while gaining enhanced durability against manufacturing loads
3Productivity
If continuous manufacturing processes are used to improve productivity, then production efficiency is improved, but unexpected loads are applied to the roughened nickel layer causing quality issues
Solution Approach 1:
The invention provides beforehand cushioning by creating an optimized roughened nickel layer structure with controlled surface texture parameters and an intermediate layer. This pre-engineered structure anticipates and cushions against unexpected loads that may occur during continuous manufacturing processes, preventing quality issues before they arise
Solution Approach 2:
By optimizing surface texture parameters (Rq: 0.29-0.90 μm, Sz: 3.5-10.0 μm) and deposition amount (3.5-19.0 g/m²), the invention creates a roughened nickel layer that maintains product quality during continuous manufacturing while enabling the necessary durability to withstand manufacturing loads
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 material achieves improved shear durability and adhesion with other members by optimizing the roughened nickel layer's surface texture, preventing breakage under multiple directional loads and ensuring stable adhesion.
Implementation Method 1
a roughened nickel layer formed on at least one side on the base material
Data Source
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AI summary
Disclosed is a nickel-plated metal material excellent in shear durability (adhesion between a base material and a roughed nickel layer when loads are applied from multiple directions to the roughened nickel layer), while having adhesion of a plating layer with the base material and adhesion with another member. [Solving Means] The nickel-plated metal material includes a base material made of metal, and a roughened nickel layer formed on at least one side on the base material. On a surface on a side of the roughened nickel layer, a root mean square height Rq is 0.29 µm or greater and 0.90 µm or smaller, and a maximum height Sz is greater than 3.5 µm and 10.0 µm or smaller.