Porous Copper Body Oxidation-Reduction Layer Conductivity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming porous copper bodies and composite parts suffer from poor thermal and electrical conductivity due to fine crystal grain sizes, which lead to increased crystal grain boundaries, and lack specific conditions for refining copper or copper alloy surfaces.
Innovation Solution
A porous copper body with a three-dimensional network structure is created by forming an oxidation-reduction layer on a sintered copper fiber skeleton, where the average crystal grain size is 5% or more of the fiber diameter, and the fibers have a diameter range of 0.05 mm to 1.0 mm with a length-to-diameter ratio of 4 to 2500, enhancing conductivity and porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If oxidation-reduction treatment is performed to form porous surface layer, then specific surface area increases and heat exchange efficiency improves, but crystal grain size becomes very fine causing deterioration of thermal conductivity and electrical conductivity
Solution Approach 1:
The invention applies different crystal grain size requirements to different regions: the oxidation-reduction layer has fine crystal grains for high specific surface area and heat exchange efficiency, while the skeleton maintains larger crystal grains for good thermal and electrical conductivity. This local differentiation resolves the contradiction between heat exchange performance and conductivity.
Solution Approach 2:
The invention creates a composite structure consisting of the oxidation-reduction layer and the skeleton, where each component has optimized properties for its specific function. The oxidation-reduction layer provides high surface area for heat exchange, while the skeleton provides structural support and maintains conductivity pathways, together forming a composite material that achieves both heat exchange efficiency and conductivity.
2Temperature
If crystal grain size of skeleton is reduced to increase surface area, then heat exchange efficiency improves, but thermal conductivity and electrical conductivity deteriorate due to increased crystal grain boundaries
Solution Approach 1:
The invention differentiates the crystal grain size between the oxidation-reduction layer and the skeleton. The skeleton maintains larger crystal grains with fewer grain boundaries to ensure good thermal and electrical conductivity, while the oxidation-reduction layer has fine crystal grains to maximize surface area for heat exchange. This local quality differentiation resolves the contradiction.
3Temperature
If copper fiber diameter is reduced to increase porosity, then heat exchange efficiency improves, but mechanical strength deteriorates
Solution Approach 1:
The invention optimizes the diameter of copper fibers within a specific range (0.05 mm to 1.0 mm) to achieve the desired balance between porosity and strength. By controlling this parameter, the invention creates sufficient porosity for heat exchange while maintaining adequate mechanical strength through the network structure of the skeleton.
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 approach results in improved thermal and electrical conductivity, high porosity, and excellent heat exchange efficiency, while maintaining dimensional accuracy and strength through the formation of a strong bond between the porous copper body and the main composite part.
Implementation Method 1
an oxidation-reduction layer formed by an oxidation step followed by a reductions step is provided on a surface of the skeleton (12)
Implementation Method 2
an oxidation-reduction layer formed by an oxidation step followed by a reductions step is provided on a surface of the skeleton (12)
Implementation Method 3
the skeleton (12) is constituted by a sintered body made of a plurality of copper fibers (11)
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A porous copper body (10, 110) including a skeleton (12) having a three-dimensional network structure is provided. An oxidation-reduction layer formed by an oxidation-reduction treatment is provided on a surface of the skeleton (12), and the average crystal grain size of an entirety including the skeleton (12) and the oxidation-reduction layer is 5% or more of the diameter of the skeleton.