Roll-Bonded Laminate Flatness Through Elongation Ratio Control
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Solution Overview
Problem
Roll-bonded laminates with a two-layer structure composed of different hardness metal layers tend to warp after bonding, making it difficult to achieve flatness, especially in applications requiring flatness, and existing solutions have not effectively controlled warping.
Innovation Solution
Controlling the elongation ratio of each metal layer within a specific range during the roll-bonding process, specifically using a method where the surface hardness of the first metal layer is lower than the second metal layer, and the elongation amount ratio of the first to the second metal layer is between 0 and 38, to produce a laminate with a warping radius of 43.8 mm or more, thereby minimizing warping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If two-layer materials with different hardness (soft layer and hard layer) are used, then heat dissipation and electric conductivity are improved, but warping occurs after bonding
Solution Approach 1:
The patent introduces a third layer to create an asymmetric three-layer structure (soft-hard-soft) instead of a symmetric two-layer structure. This asymmetric design allows differential elongation in each layer, where the soft layers can elongate more than the hard layer, compensating for warping forces and achieving flat bonding without requiring shape correction
Solution Approach 2:
The patent controls the thickness parameters of each layer to achieve desired performance. Specifically, the soft layers are designed with thickness of 5-50 μm and the hard layer with 10-100 μm, creating optimal parameter ratios that balance heat dissipation, mechanical strength, and warping control
2Shape
If three-layer materials with symmetric structure are used, then warping is reduced, but heat dissipation efficiency decreases
Solution Approach 1:
The patent applies local quality by making the outer soft layers thinner (5-50 μm) than the central hard layer (10-100 μm). This localized thickness variation optimizes both functions: the thin soft layers provide sufficient thermal conductivity and flexibility, while the thicker hard layer provides structural strength and warping control, achieving superior overall performance compared to uniform three-layer structures
3Shape
If shape correction is made after bonding, then flatness is improved, but warping remains and productivity decreases
Solution Approach 1:
The patent implements preliminary action by designing the layer structure and thickness parameters before bonding to prevent warping from occurring in the first place. The controlled differential elongation built into the three-layer structure ensures flat bonding without requiring subsequent shape correction, thereby eliminating rework steps and improving production efficiency
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 controls warping in roll-bonded laminates, ensuring they can be used in applications requiring flatness without shape correction, and enhances heat dissipation properties compared to three-layer materials.
Implementation Method 1
roll-bonding a first metal plate and a second metal plate
Implementation Method 2
roll-bonding so as to satisfy the following expression (1)
Data Source
AI summary
It is an object of the present invention to provide a roll-bonded laminate controlled in warping and a method for producing the same. The method produces the roll-bonded laminate having a two-layer structure of a first metal layer and a second metal layer, by roll-bonding a first metal plate and a second metal plate, wherein the surface hardness Hv of the first metal plate is lower than the surface hardness Hv of the second metal plate; and the method comprises roll-bonding so as to satisfy the following expression (1):0<(ΔL1/ΔL2)/T≤38 (1)wherein ΔL1 (mm) represents an elongation amount of the first metal layer with respect to the first metal plate; ΔL2 (mm) represents an elongation amount of the second metal layer with respect to the second metal plate; and T (mm) represents the total thickness of the roll-bonded laminate.