Solderable Mesh Electrode Thick Tinning Uniformity
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Solution Overview
Problem
Existing solderable mesh electrodes often have non-homogeneous coating thicknesses due to galvanic coating methods, leading to quality control issues and potential component failure, making it difficult to ensure consistent quality and reliability.
Innovation Solution
The method involves applying a thick layer of tinning to wires before weaving, followed by surface treatment with a thin metal layer to smooth the surface, and optionally adding a protective layer to enhance weaving and remove post-production, ensuring consistent solder distribution and reduced abrasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If galvanic coating method is used to apply solder layer to the mesh, then the mesh becomes solderable, but the coating thickness becomes non-homogeneous with local variations at crossing points and free wires
Solution Approach 1:
The wires are pre-coated with a thick layer of tinning (at least 10 micrometers) before the mesh is woven. This preliminary coating ensures that each wire has sufficient solderable material before assembly, eliminating the non-homogeneous coating problem that occurs with post-weaving galvanic coating methods.
Solution Approach 2:
The invention changes the coating thickness parameter from the conventional thin galvanic layer (less than 1 micrometer) to a thick tinning layer (at least 10 micrometers). This parameter change ensures homogeneous coating distribution and provides adequate solderable material throughout the mesh structure.
2Manufacturing precision
If thick layer of tinning is applied to wires before weaving, then homogeneous solderable quality is achieved, but the rough surface causes high abrasion during weaving process
Solution Approach 1:
A protective layer is applied to the thick-tinned wires before the weaving process. This protective coating prevents the rough tinning surface from causing excessive abrasion during weaving, while still allowing the thick tinning layer to provide homogeneous solderable quality in the finished mesh.
Solution Approach 2:
The protective layer acts as an intermediary between the rough thick tinning surface and the weaving machinery. It reduces direct contact and abrasion during the weaving process, making the manufacturing easier while preserving the beneficial thick coating properties.
3Quantity of substance
If thick layer of tinning is used on wires, then sufficient solderable material is provided at crossing points, but the rough surface leads to contamination and undefined properties
Solution Approach 1:
The wires are coated with a protective layer before weaving to prevent contamination during the manufacturing process. After weaving, the protective layer is removed to reveal the clean, thick tinning surface that provides sufficient solderable material without the harmful effects of process-induced contamination.
Solution Approach 2:
The protective layer is temporarily applied during manufacturing, then discarded after weaving is complete. This allows the thick tinning surface to remain clean and free from contamination that would occur if the rough surface were exposed during the weaving 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
This approach results in a more uniform solderable mesh with reduced abrasion and contamination, facilitating easier quality control and producing high-quality, reproducible meshes suitable for various applications, including electrical contacting and internal combustion engines.
Implementation Method 1
a thick layer of tinning of at least one solder is applied to at least some wires (3, 4) before production of the net (1)
Implementation Method 2
The wire provided with a thick layer of tinning can be pulled for smoothing before the network is produced, by pulling the wire through a hole, a drawing die or a template or a die
Data Source
Figure 1~4
AI summary
Solderable mesh (1) is woven from wires (2) with a thick coating (6) produced by tinning. The surfaces of the tinned wires are treated to smooth them and they are drawn before weaving. Independent claims are included for: (A) mesh electrodes containing the mesh; and (B) a method for producing the mesh by producing a thick coating on wires by tinning, surface treating to smooth them and drawing them before weaving.