Plated Composite Strip Structure With Fewer Boundary Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing composite materials through strip plating face limitations in minimum width dimensions, increased manufacturing effort, and high numbers of boundary layers, which affect electrical resistance and mechanical strength, and are prone to errors.
Innovation Solution
A method where a band arrangement with a filling channel is used, allowing the filling strip to be extruded into the channel, reducing the number of strips and interfaces, and enabling the production of narrower widths with reduced manufacturing effort and boundary layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If multiple narrow strips are used to form the composite material, then the desired narrow width sections can be achieved, but the manufacturing effort increases significantly due to additional process steps, unwinding stations, and guides
Solution Approach 1:
The filling strip is segmented during the cladding process itself - portions are extruded into the filling channel to form narrow sections while the main body continues as a single strip. This avoids the need to handle multiple separate narrow strips through the entire manufacturing process.
Solution Approach 2:
The filling channel is prepared in advance by forming recesses in the outer strips before the cladding process. This preliminary preparation allows the filling strip to be easily extruded into the pre-formed channel during cladding, eliminating the need for complex post-processing or multiple strip assembly.
2Length of moving object
If multiple strips are joined together to form the composite material, then the desired width variations can be achieved, but the number of boundary layers increases, negatively impacting electrical resistance and mechanical strength
Solution Approach 1:
Multiple strip functions are merged into a single filling strip. The filling strip serves both as the main continuous strip and as the source material for narrow sections. This merging eliminates the boundary layers that would exist between multiple separately joined strips.
Solution Approach 2:
The narrow section is nested within the structure by extruding material from the filling strip into the filling channel. The extruded portion becomes an integral part of the composite structure, eliminating the need for separate narrow strips and their associated boundary layers.
3Length of moving object
If conventional strip plating methods are used, then standard width dimensions can be produced, but very narrow widths cannot be manufactured or require immense effort
Solution Approach 1:
The filling strip serves itself by providing material for both the main strip body and the narrow sections. During the cladding process, portions of the filling strip are automatically extruded into the filling channel, eliminating the need for separate narrow strips and complex handling equipment.
Solution Approach 2:
The width parameter is dynamically changed during the cladding process itself. The filling strip transitions from its original width to form narrower sections through extrusion into the filling channel, allowing continuous variation of width without changing the number of strips or requiring multiple unwinding stations.
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
This approach allows for the production of composite materials with very small area widths and fewer boundary layers, enhancing bond properties and reducing manufacturing effort, while avoiding typical boundary surface defects.
Implementation Method 1
a portion of the filling strip is extruded into the filling channel during cladding
Implementation Method 2
The subsequent cold rolling cladding process establishes adhesion between the overlapping material surfaces
Data Source
Figure 1~4
Figure 5~7
Figure 8~11
AI summary
The invention relates to a method for producing a composite material by plating a band arrangement with a top side (O) and an underside (U), wherein the band arrangement comprises at least one first strip (1a) and one second strip (1b) which form a filling channel (2a) between one another, wherein the band arrangement comprises at least one filling strip (3a), wherein the abovementioned band arrangement is plated, wherein a part of the filling strip (3a) is extruded into the filling channel (2a) during plating, and to a composite material, characterized in that it has been produced by the method according to one of claims 1 to 14.