Stainless Steel-Cu Clad Material With Uniform Layer Thickness
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Solution Overview
Problem
The existing clad materials with stainless steel and Cu or Cu alloy layers, when roll-bonded, often result in excessively thin regions, leading to decreased weld strength and mechanical strength variability, particularly when welded to other members.
Innovation Solution
A clad material configuration where the stainless steel layers have a minimum thickness of 70% to 100% of their average thickness, with a Cu or Cu alloy layer in between, ensuring uniform thickness and bonding through a pressure-bonding load of 4.4×10^3 N/m or more during rolling, to prevent non-uniform deformation and maintain mechanical strength and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the stainless steel layers are made thinner to reduce overall thickness, then the overall thickness of the clad material is reduced, but the minimum thickness becomes excessively small causing weld strength to decrease
Solution Approach 1:
The patent applies parameter changes by precisely controlling the thickness ratio parameter. It specifies that the minimum thickness of the stainless steel layer must be 70% or more of the average thickness, transforming the design from using excessively thin layers to using layers with controlled thickness uniformity. This parameter control allows achieving both reduced overall thickness and maintained weld strength.
2Quantity of substance
If the stainless steel layers are made thinner to reduce material usage, then the amount of stainless steel is reduced, but the mechanical strength of the clad material varies
Solution Approach 1:
The patent uses parameter changes by establishing the minimum thickness as 70% or more of the average thickness. This parameter specification enables reducing the overall quantity of stainless steel while ensuring mechanical strength consistency. The controlled thickness ratio prevents excessive thinning that would cause strength variation.
Solution Approach 2:
The patent applies copying by using the average thickness as a reference standard. The minimum thickness is defined as a proportion (70% or more) of this average value, creating a controlled relationship between different regions of the layer. This copying approach ensures uniform mechanical properties while optimizing material quantity.
3Ease of manufacture
If the roll-bonding process is performed without strict thickness control, then the manufacturing process is simpler, but portions with excessively small thickness are generated
Solution Approach 1:
The patent applies parameter changes by setting the minimum thickness to 70% or more of the average thickness. This clear parameter specification provides a measurable target for the roll-bonding process, enabling manufacturers to control thickness uniformity without overly complicating the manufacturing process. The parameter serves as a practical quality control criterion.
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 configuration significantly reduces the occurrence of excessively thin regions, enhancing weld strength and mechanical homogeneity, while maintaining corrosion resistance and conductivity, making it suitable for applications like battery conductive members and heat sinks.
Implementation Method 1
clad rolling is performed with a pressure-bonding load of 4.4×10^3 N/m or more such that the clad material including a first layer made of stainless steel, a second layer made of Cu or a Cu alloy and roll-bonded to the first layer
Data Source
AI summary
A clad material (30) includes a first layer (31) made of stainless steel, a second layer (32) made of Cu or a Cu alloy and roll-bonded to the first layer, and a third layer (33) made of stainless steel and roll-bonded to a side of the second layer opposite to the first layer. The clad material has an overall thickness of 1 mm or less, and in a cross-sectional view along a stacking direction, a minimum thickness of the first layer in the stacking direction and a minimum thickness of the third layer in the stacking direction are 70% or more and less than 100% of an average thickness of the first layer in the stacking direction and an average thickness of the third layer in the stacking direction, respectively.