Thin Stainless-Copper Clad Rolling for Stable Weld Strength
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Solution Overview
Problem
The existing clad materials with stainless steel and copper alloy layers exhibit variations in thickness, leading to decreased weld strength and mechanical strength variability when welded to other members, due to excessively small thicknesses in the stainless steel layers.
Innovation Solution
A clad material with a stainless steel first layer, a copper or copper alloy second layer, and a stainless steel third layer, where the minimum thickness of each layer is set to 70% or more and less than 100% of the average thickness, ensuring uniformity and preventing excessively small thicknesses, thereby maintaining consistent weld strength and mechanical properties.
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 clad material becomes more suitable for thin-layer applications, but the weld strength decreases and mechanical strength varies
Solution Approach 1:
The patent applies local quality control by specifying that the minimum thickness of the first and third stainless steel layers must be 70% or more of their respective average thicknesses. This ensures that local regions (thinnest portions) maintain sufficient thickness for weld strength while allowing the overall thickness to be reduced to 1 mm or less, resolving the contradiction between thinness and strength.
2Volume of moving object
If the stainless steel layers are made thinner to reduce overall thickness, then the clad material becomes more suitable for thin-layer applications, but the mechanical strength varies
Solution Approach 1:
By controlling the minimum thickness to be 70% or more of the average thickness, the patent ensures uniform mechanical properties throughout the clad material. This prevents excessive thickness variation that would cause mechanical strength inconsistency, while still enabling overall thickness reduction for thin-layer applications.
Solution Approach 2:
The patent changes the thickness parameter specification from a fixed average value to a range-based control (minimum 70% of average), which stabilizes mechanical strength by preventing extreme thinness while allowing flexibility in overall thickness design.
3Strength
If the minimum thickness of stainless steel layers is increased to improve weld strength, then welding quality improves, but the overall thickness and weight increase
Solution Approach 1:
The patent applies local quality control by setting the minimum thickness threshold at 70% of the average thickness, ensuring sufficient weld strength only where needed (at the thinnest portions) rather than uniformly increasing thickness throughout. This maintains weld quality while minimizing overall weight increase.
Solution Approach 2:
The patent uses a ratio-based parameter (minimum/average thickness ≥ 70%) rather than a fixed absolute minimum thickness. This allows optimization of weld strength relative to overall thickness, enabling weight reduction while maintaining adequate weld quality through proportional control.
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 small thicknesses in the clad material, enhancing weld strength and mechanical stability, particularly effective in thin layers (1 mm or less), and ensures non-magnetic properties for compatibility with electronic components.
Implementation Method 1
clad rolling for rolling and bonding a first metal plate made of stainless steel, a second metal plate made of Cu or a Cu alloy, and a third metal plate made of stainless steel
Implementation Method 2
rolling and bonding... in a state in which the first metal plate, the second metal plate, and the third metal plate are stacked
Data Source
AI summary
The method is for manufacturing a clad material (30), which includes: clad rolling for rolling and bonding a first metal plate (131) made of stainless steel, a second metal plate (132) made of Cu or a Cu alloy, and a third metal plate (133) made of stainless steel in a state in which the first metal plate, the second metal plate, and the third metal plate are stacked in this order. The clad rolling is performed with a pressure-bonding load of 4.4×103 N/mm or more. The second layer is made of Cu or a Cu alloy. The third layer is made of stainless steel. The clad material has an overall thickness of 1 mm or less.