Improved cable connectors

Abstract

A brazable-ready cable connector made of conductive material for attaching a cable to a workpiece is provided, the brazable-ready cable connector comprising a plate portion having a first surface for attachment to a workpiece, a cable receiving portion for receiving a cable, and a sheet of brazing material provided on the first surface of the plate portion, wherein the sheet of brazing material is attached to the first surface by ultrasonic welding.

Description

Technical Field

[0005] , ,

[0006]

[0001] The present invention relates to cable connection parts of conductive materials, more specifically, cable connection parts for attachment to a workpiece by a brazing process, and a method for manufacturing the same.

Background Art

[0002] The trend in railway transportation is towards vehicles that run at higher speeds and with heavier axle loads. This has increased the requirements for the strength and wear resistance of rails. Therefore, rails are manufactured from high-alloy steel to meet more stringent requirements. The high-alloy steel used for rails is highly sensitive to thermal stresses that can cause a structural change known as martensite formation (or hardening effect). Martensite formation can cause cracks in the rail material, and due to heavier loads, rail damage can have devastating consequences for railway transportation.

[0003] In many cases, it is necessary to attach a cable or wire (e.g., a signal wire) to a rail. A common method of attaching a cable or wire is to use a connection part such as a cable shoe. A permanent connection between the cable and the rail is desired, but if it is difficult or impossible to achieve a direct connection, preferably a cable shoe is used.

[0004] These cables or wires need to be firmly and safely attached to the rail to reduce the risk of loosening, rail cracking, and / or other rail damage.

[0005] Therefore, it is extremely important that the cable or wire be attached to the rail in a way that does not cause martensite formation.

[0006] The risk of martensite formation can be reduced by using known temperature-controlled brazing processes. The brazing process requires supplying brazing material to the cable shoe. However, known methods for supplying brazing material to cable shoes are complex and difficult to use.

[0007] From the above, it is understood that there is room for improvement, and the present invention aims to solve or at least mitigate the above and other problems. [Overview of the project]

[0008] The present invention is defined by the appended independent claims. Further features and advantages of the concepts disclosed herein are described below, some of which will become apparent from the description or may be understood through the practice of the described art. These features and advantages of the concepts may be realized and obtained by means and combinations specifically indicated in the appended claims. These and other features of the described art will become more apparent from the following description and the appended claims or may be understood through the practice of the concepts disclosed herein.

[0009] According to a first embodiment, a brazable-ready cable connector made of conductive material for attaching a cable to a workpiece is provided, the brazable-ready cable connector comprising a plate portion having a first surface for attachment to a workpiece, a cable receiving portion for receiving a cable, and a sheet of brazing material provided on the first surface of the plate portion, wherein the sheet of brazing material is attached to the first surface by ultrasonic welding.

[0010] Preferably, the brazing material contains silver.

[0011] Preferably, the brazing material sheet is in direct contact with the first surface of the plate portion.

[0012] Preferably, the ultrasonic welding includes a plurality of ultrasonic spot welds that form a first knurl pattern on a sheet of brazing material.

[0013] Preferably, the first surface is provided with a second knurled pattern.

[0014] Preferably, the second surface of the plate portion opposite to the first surface is provided with a third knurled pattern.

[0015] A second aspect provides a method for manufacturing a brazed-ready cable connector, the method comprising the steps of: providing a cable connector having a plate portion and a cable receiving portion; providing a sheet of brazing material; placing the sheet of brazing material on a first surface of the plate portion; and ultrasonically welding the sheet of brazing material to the first surface using an ultrasonic welding device so as to attach the sheet of brazing material to the first surface.

[0016] Preferably, the brazing material contains silver.

[0017] Preferably, the ultrasonic welding step includes performing multiple ultrasonic spot welds.

[0018] Preferably, the method further includes the step of imprinting a first knurled pattern onto a sheet of brazing material by a plurality of ultrasonic spot welds.

[0019] Preferably, the method further includes the step of imprinting a second knurled pattern on a first surface by a plurality of ultrasonic spot welds.

[0020] Preferably, the ultrasonic welding step includes applying a holding force to the cable connection component using an ultrasonic welding device, and imprinting a third knurled pattern on the second surface of the plate portion opposite to the first surface using the holding force.

[0021] Preferably, the steps of ultrasonic welding and imprinting on the second surface are performed in a single pressing motion.

[0022] According to a third embodiment, a method for brazing a cable shoe to a workpiece is provided, the method comprising: manufacturing a braze-ready cable connector according to the method of the second embodiment; placing the braze-ready cable connector against a workpiece to bring the sheet of braze material of the braze-ready cable connector into contact with the workpiece; pressing the electrode of a braze gun against the braze-ready cable connector; enabling current to flow from the power supply of the braze gun through the electrode to the braze-ready cable connector; generating an electric arc by forming a gap between the electrode and the braze-ready cable connector; and forming a bond between the braze-ready cable connector and the workpiece by melting the sheet of braze material with heat transmitted through the cable connector. [Brief explanation of the drawing]

[0023] More specific descriptions are provided below and illustrated with the accompanying drawings to best illustrate how the above-described embodiments are carried out and to define other advantages and features of this disclosure. It should be understood that these drawings only illustrate exemplary embodiments of the invention and should not be considered to limit its scope, and such examples are described and illustrated in more specific and detail with reference to the accompanying drawings.

[0024] [Figure 1a] A perspective view of the cable connection component is shown. [Figure 1b] A side view of the cable connection component is shown. [Figure 1c] A cross-sectional view of a cable connection component is shown. [Figure 1d] A front view of the cable connection component is shown. [Figure 1e] Shows a perspective view of a cable connection component. [Figure 1f] Shows a perspective view of a cable connection component. [Figure 2a] Shows a prior art brazing clip. [Figure 2b] Shows a cable connection component with a brazing clip. [Figure 2c] [[ID=十三]]Shows a cross-section of a cable connection component with a brazing clip. [Figure 2d] Shows a prior art brazing clip. [Figure 2e] Shows the manufacturing steps of a cable connection component with a brazing clip. [Figure 2f] Shows a cable connection component with a brazing clip. [Figure 3a] Shows a brazing gun for attaching a cable connection component to a workpiece. [Figure 3b] Schematically shows a brazing gun for attaching a cable connection component to a workpiece. [Figure 3c] Shows a detailed view of a brazing gun for attaching a cable connection component to a workpiece. [Figure 4a] Shows the principle of a brazing gun. [Figure 4b] Shows the principle of a brazing gun. [Figure 5] Shows how to use a brazing gun. [Figure 6a] Shows a perspective view of a cable connection component according to an embodiment. [Figure 6b] Shows a side view of a cable connection component according to an embodiment. [Figure 6c] Shows a bottom view of a cable connection component according to an embodiment. [Figure 7] Shows a device for ultrasonic welding. [Figure 8] Shows a method for manufacturing a cable connection component according to an embodiment. [Figure 9] Shows a method for attaching a cable connection component according to an embodiment to a workpiece.

[0025] Furthermore, in drawings, the same reference numeral indicates the same or corresponding element or part across multiple drawings. The first digit of the reference numeral indicates the drawing in which the corresponding element or part first appears. [Modes for carrying out the invention]

[0026] Various embodiments of the disclosed methods and arrangements are described in detail below. While specific embodiments are described, it should be understood that this is done for illustrative purposes only. Those skilled in the art will recognize that other components, configurations, and steps may be used without departing from the spirit and scope of the invention as described in the claims.

[0027] In this specification and subsequent sections, specific embodiments are described in more detail with reference to the accompanying drawings. It will be apparent to those skilled in the art that various changes and modifications can be made without departing from the concept of the present invention. Other embodiments will also be apparent to those skilled in the art through examination of the specifications and practices disclosed herein. Since everything is obvious to those skilled in the art, it should be understood that elements and materials can be substituted with those illustrated and described herein, parts and processes can be replaced or omitted, certain features can be used independently, and embodiments or features of embodiments can be combined.

[0028] The embodiments described herein are provided as examples to make this disclosure thorough and complete and to fully convey the scope of the concept of the invention, and the claims should be construed to include all modifications, equivalents and substitutions of the concept of the invention that would be obvious to those skilled in the art relating to the concept of the invention. Unless otherwise specified, different embodiments may be combined with each other.

[0029] The embodiment relates to a cable connector made of a conductive material that is attached to a workpiece by a temperature-controlled brazing process. When the workpiece is made from a material including steel or alloy steel, the temperature-controlled brazing process ensures that the resulting braze is at least substantially martensite-free, preferably martensite-free. That is, the braze is obtained without substantially harmful structural changes (martensite formation) in the crystalline structure of the workpiece. In other words, it is possible to obtain a braze that does not produce martensite formation at all or substantially using a temperature-controlled brazing process.

[0030] Brazing that does not involve martensite is particularly advantageous, for example, when attaching connecting parts to components of railway tracks (e.g., railway rails), pipelines, wind turbines, and nuclear power plants.

[0031] For example, using temperature-controlled brazing processes and cable connection components, • One or more cables on the rails of a railway track, • To prevent corrosion, one or more anodes are installed in pipelines or vessels (e.g., tankers), and / or For example, one or more lightning rods or lightning connectors on a wind turbine It can be attached.

[0032] In particular, embodiments relate to cable connection components prepared for attachment to a workpiece by a temperature-controlled brazing process described, and methods for manufacturing and / or producing them.

[0033] Figures 1a to 1f show cable connection components 100 made of conductive material. The exemplary cable connection component 100 shown in Figures 1a to 1d is a cable shoe. The cable connection component 100 shown in Figure 1e is a single-legged cable connector for use with a cable shoe. The cable connection component 100 shown in Figure 1f is a double-legged cable connector for use with a cable shoe. The cable connection component 100 may also be a cable lug, cable holder, cable terminal, etc.

[0034] The cable connector 100 is a connector configured to connect a cable or wire to a workpiece (e.g., rails of a railway track). The cable connector 100 is preferably used when a permanent connection between the cable and the workpiece is desired, but it is difficult or impossible to achieve a direct connection or mounting between the cable and the workpiece. Examples of cables or wires include, but are not limited to, signal cables, signal wires, lightning rods or lightning connectors, anodes for corrosion protection, or any other cables or wires to which connection to a workpiece is desired.

[0035] The cable connector 100 is manufactured from at least partially conductive material so that it can transmit electrical signals from the cable or wire it receives to the workpiece. Preferably, the conductive material includes a metal. More preferably, the conductive material includes copper and / or a copper alloy. In embodiments, the cable connector 100 may be manufactured from copper and / or a copper alloy.

[0036] The cable connector 100 according to this embodiment is intended to be attached to a workpiece by a temperature-controlled brazing process. An exemplary temperature-controlled brazing process is described in more detail with reference to Figures 3 to 5. It will be understood that the cable connector 100 according to this embodiment is not limited to use in the temperature-controlled brazing process described, but may be used in any suitable brazing process for attachment to a workpiece.

[0037] The cable connector 100 may comprise a plate portion 101 and a cable receiving portion 102. The plate portion 101 is a substantially flat plate. The plate portion 101 is configured to be attached to a workpiece. In particular, the first surface 101a of the plate portion 101 is configured to be brazed in contact with the workpiece so as to attach the first surface 101a to the workpiece. The plate portion 101 may be substantially solid and / or small in size. Alternatively, the plate portion 101 may have one or more through holes (not shown) between the first surface 101a and a second surface 101b opposite to the first surface 101a.

[0038] The cable receiving section 102 is configured to receive cables or electric wires. The cable receiving section 102 can receive cables or electric wires directly or indirectly.

[0039] Figures 1a to 1d show a cable connector 100 having a cable receiving section 102 configured to directly receive an electric wire. This type of cable connector 100 may be referred to as a cable shoe. The cable receiving section 102 of the cable shoe includes a cable cavity 103 for receiving a cable or electric wire. The shape and / or size of the cable cavity 103 may be determined according to the shape and / or size of the cable or electric wire to be received. The cable receiving section 102 may further be designed so that the cable cavity 103 extends into a tapered cavity 104. The tapered cavity 104 has a tapered cross-section. When a cable is received into the cable cavity 103, the tapered shape of the tapered cavity 104 ensures that the tapered cavity 104 is not at least partially occupied by the cable. Thus, the tapered cavity 104 can reduce the amount of heat transferred to the cable through the cable shoe when the cable shoe is attached to the workpiece by a brazing process. Therefore, the tapered cavity 104 reduces the amount of power required to carry out the brazing process.

[0040] In this embodiment, the cable shoe may be formed by pressing a pipe or tube such that a portion of the pipe or tube is flattened (thus forming a plate portion 101), and the other portion remains substantially circular to form a cable cavity 103 for receiving a cable or wire. The pressing of the pipe or tube also advantageously ensures that a tapered cavity 104 is formed between the plate portion 101 and the cable cavity 103.

[0041] On the other hand, Figures 1e and 1f show a cable connection component 100 having a cable receiving section 102 configured to indirectly receive an electric wire. This type of cable connection component 100 may be called a cable connector. A cable connector may be used with an intermediate connecting member 105 (such as a cable shoe or cable lug) that provides connection to a cable or electric wire.

[0042] The cable connector comprises at least one leg and a cable receiving portion 102. The at least one leg includes a plate portion 101 for attachment to a workpiece. The plate portion 101 of the cable connector is substantially similar to or identical to the aforementioned plate portion 101.

[0043] Cable connectors can have multiple legs. For example, a cable connector may have two, three, or more legs. The more legs there are, the greater the contact area with the workpiece. Therefore, cable connectors with multiple legs can be used with larger cables (i.e., cables with a larger cross-sectional area).

[0044] The cable receiving portion 102 of the cable connector is configured to indirectly receive a cable or electric wire. For example, the cable receiving portion 102 may be configured to receive an intermediate connecting member 105. The cable receiving portion 102 may include connecting means for connecting to the intermediate connecting member 105. The connecting means may include a threaded member to which the intermediate connecting member 105 can be attached. The intermediate connecting member may be fixed in a predetermined position on the connecting means by a fixing member 106, such as a nut.

[0045] The intermediate connecting member 105 may include a cable cavity 103 for receiving a cable or wire. Therefore, when the intermediate connecting member 105 is attached to the cable receiving section 102 (via a connecting means), contact is provided between the cable and the cable connector.

[0046] To attach the cable connector 100, as shown in Figures 1a to 1f, to the workpiece by brazing, a brazing is performed between the cable connector 100 and the workpiece. The material (for example, a metal such as silver) is generally provided.

[0047] Since the brazing material has a lower melting point than the cable connector 100, the brazing material can be melted without melting the cable connector 100. This allows the integrity of the cable connector 100 to be maintained during the brazing process. Therefore, the brazing material can be melted during the brazing process so as to form a strong bond between the cable connector 100 and the workpiece after the brazing process. This bond has high strength and allows the cable connector 100 to be firmly attached to the workpiece. In addition, this bond ensures good thermal and electrical conductivity between the cable connector 100 and the workpiece.

[0048] Figures 2a to 2c show a known brazing clip 200 described in patent application number SE0101688-0. Figures 2d to 2f show a different known brazing clip described in patent application number EP04732538.6, which is crimped onto a cable connector 100. The brazing clips 200 shown in Figures 2a to 2f are used with a cable connector 100 as shown in Figures 1a to 1f.

[0049] The brazing clip 200 is manufactured from the brazing material and crimped onto a predetermined position on the cable connector 100. Thus, the brazing clip 200 ensures that the brazing material is held in place between the cable connector 100 and the workpiece during the brazing process. The brazing clip 200 comprises a flat portion 201 positioned against the first surface 101a of the plate portion 101 of the cable shoe 100, and one or more flanges 202 bent and crimped onto the plate portion 101 of the cable connector.

[0050] The brazed clip 200 is positioned around the plate portion 101 of the cable shoe 100 and crimped to the plate portion 101. This secures the brazed clip 200 in place by one or more flanges 202.

[0051] The brazing material within the brazing clip 200 needs to be bent and crimped onto the cable connector 100 to form the flange 202 (see, for example, Figures 2d to 2f), and the brazing material needs to be subjected to an annealing process before the brazing clip 200 can be attached to the cable connector 100. In other words, the brazing material needs to be heat-treated to become more ductile so that it can be softened and bent. For example, when using silver as the brazing material, the brazing material needs to be annealed before the brazing clip 200 can be crimped onto the cable connector 100. The inventors are aware that the annealing process may cause oxidation or other undesirable chemical reactions on the surface of the brazing material. The brazing clip 200 shown in Figures 2a to 2c is designed to be larger than the plate portion 101 of the cable connector 100 and to protrude next to it (see Figure 2b). This reduces the amount of moisture that can penetrate between the cable connector 100 and the workpiece due to capillary forces, thereby reducing the risk of corrosion. The penetration of moisture can negatively affect the mechanical strength of the brazed joint. Furthermore, the larger size of the brazed clip 200 compared to the cable connector 100 results in a larger bonding surface area and lower electrical resistance between the workpiece and the cable connector 100.

[0052] When brazing a cable connector 100 to a workpiece, a flux material may be provided between the brazing clip 200 and the workpiece when brazing the connector 100 to the workpiece. The flux material can then be activated during the brazing process. The flux material ensures that the joint surfaces of both the brazing clip 200 and the workpiece are cleaned and moistened before the brazing process. The flux material also prevents oxidation from occurring on the surfaces. The flux material should have good thermal conductivity to facilitate heat transfer during the brazing process. Furthermore, the flux material should be suppressed by the molten brazing material during the brazing process.

[0053] Figures 3a to 3c show the use of a brazing gun 301 to attach the cable connector 100 to the workpiece 302.

[0054] Figure 3a shows a cable connector 100 being attached to a workpiece 302 (in the form of a rail) using a brazing gun 301 configured to perform a temperature-controlled brazing process. The cable connector 100 is firmly brazed to the head of the rail. Brazing may also be performed on the web portion or foot portion of the rail.

[0055] Figure 3b shows a brazing gun 301 for use in a temperature-controlled brazing process. The brazing gun 301 comprises a power supply 303, a control unit 304, a switch 305, a lifting magnet 306, and an electrode 307.

[0056] The power supply 303 may be an internal power source such as a battery, or an external power source connected via a power supply interface such as a power supply cable. The power supply 303 is configured to supply power to the brazing process under the control of the control unit 304.

[0057] The control unit 304 is configured to adjust the current and voltage supplied during the brazing process. For example, the control unit 304 can adjust or control the power consumption and / or operating time during the brazing process. This allows the control unit 304 to ensure that sufficient brazing is achieved. The control unit 304 can also ensure that the brazing process is carried out with reduced or minimal energy consumption.

[0058] The switch 305 may be a button or lever on the brazing gun 301 that a user can press or activate to start and / or end the brazing process. For example, pressing the switch 305 can close the electrical circuit of the brazing gun 301.

[0059] The lifting magnet 306 is an electromagnet that can be operated by the control unit 304 and / or switch 305. The lifting magnet 306 can lift (i.e., move) the electrode 307.

[0060] The electrode 307 is preferably a carbon electrode. The electrode 307 may be placed in an electrode holder that allows interaction with the lifting magnet 306. For example, the electrode holder may be made from a magnetic material.

[0061] The brazing gun 301 may include an electrical circuit connecting a power supply 303, a control unit 304, a switch 305, and a lifting magnet 306.

[0062] The brazing gun 301 is described in detail in patent applications SE0101688-0 and EP21167588.9.

[0063] To begin the brazing process, the user places the cable connector 100 (equipped with a brazing clip 200) against the workpiece 302 and presses the brazing gun 301 against the second surface 101b of the plate portion 101 of the cable connector 100. Thus, at the start of the brazing process, the electrode 307 is pressed against the cable connector 100. This can be seen in Figure 3b. Note that the electrical circuit is completed by the workpiece acting as a ground.

[0064] After this, the user presses switch 305 to close the electrical circuit, allowing current to flow from power supply 303 to cable connector 100. Since electrode 307 is initially in contact with cable connector 100, the electrical circuit of the brazing gun is effectively short-circuited.

[0065] Subsequently, as shown in the detailed view in Figure 3c, the control unit 304 is configured to operate the lifting magnet 306 so that the lifting magnet 306 lifts the carbon electrode 307 from the cable connector 100. This separates the electrode 307 from the cable connector 100 at a certain height. The separation and the potential difference across the gap generate an electric arc 308. The electric arc 308 strikes the second surface 101b of the plate portion 101 of the cable connector 100. Thus, the cable connector 100 forms one pole (e.g., negative pole), while the electrode 307 forms the opposite pole (e.g., positive pole). It will be understood that the brazing process is not limited to the specific arrangement of polarities shown in Figure 3c, and that reverse polarity is also possible, as described in relation to Figure 4.

[0066] The electric arc 308 heats the cable connector 100, and the heat is transferred through the plate portion 101 of the cable connector 100, melting the brazing material in the brazing clip 200. This forms a brazed joint between the cable connector 100 and the workpiece 302. As a result, the cable connector 100 is firmly brazed to the workpiece 302 without the electric arc 308 directly contacting the workpiece 302.

[0067] In this temperature-controlled brazing process, the plate portion 101 of the cable connector 100 acts as a thermal buffer against localized overheating of the workpiece 302. The cable connector 100 also provides a relatively uniform temperature distribution across the entire molten surface. Therefore, martensite formation in the workpiece 302 can be prevented.

[0068] Figure 4 illustrates the basic principle of the brazing gun 301 during the brazing process. Figure 4a shows the brazing process with electrode 307 acting as the positive electrode. Figure 4b shows the reverse configuration with electrode 307 acting as the negative electrode.

[0069] During the brazing process, electrons and / or ions flow between the cable connector 100 and the electrode 307. The direction of the ions and / or electrodes depends on the polarity of the electrode 307.

[0070] The elliptical region shown in Figure 4, which indicates the arc width, also shows that using the polarity corresponding to the negative electrode 307 results in a thinner, more focused arc, while connecting electrode 307 to the positive electrode produces a wider or blurred arc. This effect has shown in tests that selecting the negative electrode for electrode 307 reduces the energy required for brazing.

[0071] Figure 5 shows a brazing method using a brazing gun 301.

[0072] In step 501, the user provides the cable connector 100 and the brazing clip 200.

[0073] In step 503, the user crimps the brazed clip 200 onto the cable connector 100.

[0074] In step 505, the user places the cable connector 100 relative to the workpiece. The workpiece may be a rail of a railway track. The cable connector 100 is placed relative to the workpiece such that the flat portion 201 of the brazed clip 200 is in contact with the workpiece.

[0075] In step 507, the user presses the electrode 307 of the brazing gun 301 against the cable connector 100. The electrode 307 is pressed against the side of the cable connector 100 opposite to the side of the brazing clip 200 on which the flat portion 201 is provided.

[0076] In step 509, current is enabled to flow from the power supply 303 of the brazing gun 301 through the electrode 307 to the cable connection component 100. For example, current can be enabled by closing the switch 305.

[0077] In step 511, an electric arc 308 is generated by creating a gap that separates the electrode 307 from the cable connection component 100. The electric arc 308 is generated by a potential difference across the gap, which is maintained by the power supply 303 and the control unit 304 of the brazing gun 301.

[0078] In step 513, the brazing material in the brazing clip 200 is melted by the heat transmitted through the cable connector 100 to form a bond between the cable connector 100 and the workpiece.

[0079] Figures 6a to 6c show a cable connector 600 prepared for a brazing process according to an embodiment. The cable connector 600 may be referred to as a brazing-ready cable connector 600. The brazing-ready cable connector 600 is identical to the aforementioned cable connector 100 shown in Figure 1, but the brazing-ready cable connector 600 further comprises a brazing sheet 601. The brazing sheet 601 is attached to the cable connector 600 by ultrasonic welding.

[0080] In this embodiment, the brazing sheet 601 can be directly attached to the plate portion 101 of the brazing-ready cable connector 600. In other words, the brazing sheet 601 can be in direct contact with the surface 101a of the plate portion 101.

[0081] The brazed sheet 601 is made from a brazing material. The brazing material preferably contains silver. Preferably, the brazing material contains 30-80 wt% silver, 40-70 wt% silver, 50-60 wt% silver, or 54-56 wt% silver. More preferably, the brazing material contains 54-56 wt% silver (Ag), 20-22 wt% copper (Cu), 20-24 wt% zinc (Zn), and 1.5-2.5 wt% tin (Sn). For example, the brazing material contains about 55 wt% silver (Ag), about 21 wt% copper (Cu), about 22 wt% zinc (Zn), and about 2 wt% tin (Sn). For example, the brazing material may be a material that meets the international standard Ag155 according to ISO 17672.

[0082] The brazing sheet 601 may be a substantially flat plate. The size of the brazing sheet 601 may be determined according to the size of the brazing-ready cable connector 600, in particular the size of the plate portion 101, and more particularly the size of the second surface 101b of the plate portion 101. For example, the size of the brazing sheet 601 may be determined to cover most of the second surface 101b of the plate portion 101, or substantially the entire second surface 101b of the plate portion 101.

[0083] The shape of the brazing sheet 601 may be determined according to the shape of the brazing-ready cable connector 600, in particular according to the shape of the plate portion 101, and more particularly according to the shape of the second surface 101b of the plate portion 101. For example, the shape of the brazing sheet 601 may be determined to cover most of the second surface 101b of the plate portion 101, or substantially the entire second surface 101b of the plate portion 101.

[0084] Since the brazing sheet 601 does not extend outside the plate portion 101 and / or does not have a flange that bends over the plate portion 101, the amount of brazing material can be significantly reduced. Tests have shown that the brazing-ready cable connector 600 according to the embodiment can use approximately 50% less brazing material compared to the cable connector 100 with the brazing clip 200.

[0085] Furthermore, since the brazed sheet 601 is a flat sheet without flanges that need to be bent on the plate portion 101 and / or pressed onto the plate portion 101, the brazing material does not need to be subjected to an annealing process before the brazed sheet is attached to the cable connection component. This reduces manufacturing costs and complexity.

[0086] The brazing sheet 601 may be thin. Preferably, the brazing sheet 601 has a thickness of 0.1 to 1 mm, more preferably 0.15 to 0.5 mm, even more preferably 0.2 to 0.3 mm, and even more preferably about 0.25 mm.

[0087] Ultrasonic welding ensures that the brazing sheet 601 is held in place on the brazing-ready cable connector 600 throughout the brazing process. Furthermore, the brazing-ready cable connector 600, with the brazing sheet 601 attached, can be manufactured well in advance of the brazing process and stored for extended periods.

[0088] Ultrasonic welding ensures that the brazing sheet 601 is firmly attached to the plate portion 101 of the brazed-ready cable connector 600. Furthermore, ultrasonic welding reduces or eliminates the space or volume between the brazing sheet 601 and the plate portion 101, thereby reducing or eliminating adverse effects of air, moisture, and / or other contaminants on the surface between the brazing sheet 601 and the plate portion 101. This significantly reduces (or eliminates) oxidation on the back side of the brazing sheet 601, resulting in a longer shelf life for the brazed-ready cable connector 600.

[0089] Furthermore, the inventors have recognized that the vibrational and frictional forces generated during the ultrasonic welding process remove oxides present on the surface between the brazed sheet 601 and the plate portion 101, and prevent further oxidation of the surface.

[0090] Figure 7 shows an apparatus for ultrasonic welding that may be used to manufacture brazable-ready cable connectors 600 according to an embodiment. This apparatus comprises an anvil 701, a horn 702, and a transducer. A suitable ultrasonic welding apparatus is the Branson GMX-20MA manufactured by Emerson Electric Co.

[0091] The ultrasonic welding apparatus is configured to convert high-frequency electrical energy into mechanical vibration energy via a transducer. This causes the horn 702 to vibrate at an ultrasonic frequency. The frequency may be 20 to 60 kHz, preferably 20 to 40 kHz, more preferably 20 to 30 kHz, even more preferably 20 to 25 kHz, and still more preferably 20 to 22 kHz. In one embodiment, the frequency is approximately 20 kHz.

[0092] The amplitude of the vibration may be 4 to 90 micrometers, preferably 15 to 75 micrometers, and more preferably 20 to 60 micrometers.

[0093] The apparatus may be configured to apply a retaining force (F) to hold the brazed-ready cable connector 600 in place between the horn 702 and the anvil 701. The magnitude of the retaining force is preferably 800 to 4000 N, more preferably 1000 to 3000 N, and even more preferably 1500 to 2600 N.

[0094] The pressure acting on the brazed sheet 601 may be 0.1 to 1 MPa (MPa = 1,000,000 Pascals), preferably 0.2 to 0.5 MPa, and more preferably 0.25 to 0.4 MPa.

[0095] Horn 702 can be vibrated vertically (i.e., parallel to the direction of the coercive force), horizontally (i.e., perpendicular to the direction of the coercive force), or both vertically and horizontally.

[0096] Therefore, when pressed down by the holding force, the horn 702 acts on the brazed sheet 601, generating high-frequency friction between the brazed sheet 601 and the plate portion 101 until the surfaces of the brazed sheet 601 and the plate portion 101 are heated and welded together.

[0097] Importantly, the heat generated (by friction) during the ultrasonic welding process is sufficient to weld the brazing sheet 601 to the plate portion 101 of the brazing-ready cable connector 600, but insufficient to completely melt the brazing sheet 601. In particular, the shape of the brazing sheet 601 can be substantially maintained during the ultrasonic welding process.

[0098] The horn 702 may have one or more knurlings 703 (e.g., teeth and / or cavities) on the welding surface (e.g., the lower surface in Figure 8) for forming one or more spot welds. Alternatively, the horn 702 may have one or more wedges for forming one or more line welds. As yet another alternative, the horn 702 may have a flat surface or a blank surface. The use of spot welding or line welding can significantly reduce the power or energy required to carry out the ultrasonic welding process.

[0099] The knurling 703 may have any shape, including but not limited to pyramidal, conical, hemispherical, elliptical, cylindrical, cubic, cubic, prism-shaped, polyhedral, and / or tetrahedral shapes. The base of the knurling may be rhombic, circular, elliptical, rectangular, square, hexagonal, and / or polygonal. The cross-section of the knurling may be rhombic, circular, elliptical, rectangular, square, hexagonal, and / or polygonal.

[0100] The knurling 703 may be either a female mold, for example, a cavity in the weld surface, or a male mold, i.e., teeth protruding from the weld surface.

[0101] The knurling 703 may have a height h of 0.3 to 0.7 mm. For example, the knurling 703 may have a height h of 0.65 mm. The knurling 703 may have a width w of 0.6 to 1.4 mm. For example, the knurling 703 may have a width w of 1.3 mm. The knurling 703 may have an angle α (alpha) of 30 to 60 degrees. For example, the knurling 703 may have an angle α (alpha) of 45 degrees.

[0102] A knurling arrangement can be formed for a horn 702 having multiple knurling marks 703. The knurling arrangement may comprise knurling marks 703 arranged in rows and columns. The knurling arrangement may comprise one or more rows, each having multiple knurling marks 703. Additionally or alternatively, the knurling arrangement may comprise one or more columns, each having multiple knurling marks 703. For example, the knurling arrangement may comprise knurling marks 703 arranged along the outer perimeter (e.g., a rectangle) of the horn 702.

[0103] Rows may be perpendicular to columns. For example, the knurling 703 may be arranged in a grid. Alternatively, rows may be inclined to columns at any suitable angle, e.g., 30 degrees, 45 degrees, or 60 degrees. In other words, rows and / or columns may be moved relative to adjacent rows and / or columns. For example, the knurling 703 may be arranged in a grid that is moved, deflected, or inclined.

[0104] The knurling 703 in rows and / or columns may be at constant intervals, or alternatively, the distance between the knurling 703 may vary. For example, rows and / or columns of knurling arrangement may have 3 to 30 knurlings per centimeter, more preferably 5 to 20 knurlings per centimeter, and most preferably 7 to 15 knurlings per centimeter.

[0105] Alternatively, the knurling arrangement may consist of irregularly arranged knurling 703.

[0106] Due to the presence of the knurling arrangement in the horn 702, when ultrasonically welded to the cable connector 100, the knurling pattern 602 can be imprinted on the brazing sheet 601. This is shown in Figure 6. Such a knurling pattern 602 imprinted on the brazing sheet 601 has been found to be advantageous for at least the following reasons:

[0107] The multiple mounting (i.e., welding) points provided by the horn 702 with its knurled arrangement (and corresponding knurled pattern 602 on the brazing sheet 601) improve thermal and electrical conductivity between the plate portion 101 and the brazing sheet 601. This ensures a power-efficient brazing process in which the cable connection component is firmly attached to the workpiece without forming martensite.

[0108] In particular, for brazable-ready cable connectors 600 intended for use on rails of railway tracks or other vibrating workpieces, another important advantage is that the strength of the brazed joint between the workpiece (e.g., rail) and the brazable-ready cable connector 600 is dramatically improved by the knurled pattern 602. During the ultrasonic welding process, the knurled pattern 602 is not only imprinted on the brazing sheet 601 (due to the knurling arrangement in the horn 702), but also on the first surface 101a of the brazable-ready cable connector 600 on the underside of the brazing sheet 601. This is due to the thin thickness of the brazing sheet 601, and therefore the forces from the horn 702 also affect the first surface 101a. Thus, the first surface 101a may also have the knurled pattern 602, i.e., a wavy first surface 101a. The knurling pattern 602 on the first surface 101a may be similar to or identical to the knurling pattern 602 on the brazed sheet 601, for example, the distribution of the knurling may be similar or identical. However, the depth of the knurling pattern 602 on the first surface 101a may be less than the depth of the knurling pattern 602 on the brazed sheet 601.

[0109] This wavy first surface 101a increases the effective surface area of ​​the first surface 101a that is brazed to the workpiece. Therefore, the strength of the brazed joint is improved. As mentioned above, this is particularly important for brazable-ready cable connectors 600 that are brazed to rails of railway tracks, because the rails are subjected to a considerable amount of vibration each time a train passes. Similarly, it is also advantageous for other workpieces that are subjected to vibration.

[0110] Additionally or alternatively, during the ultrasonic welding process, the anvil 701 may be provided with a knurling arrangement that allows a knurling pattern 602 to be imprinted on the second surface 101b of the cable connector 100. The knurling arrangement of the anvil 701 may be similar to or identical to the knurling arrangement of the horn 702. Alternatively, the knurling arrangement of the anvil 701 may be different from the knurling arrangement of the horn 702.

[0111] Therefore, the holding force applied during the ultrasonic welding process can also be utilized to function as an imprinting force for imprinting the knurled pattern 602 onto the second surface 101b of the plate portion 101. In other words, the knurled pattern 602 can be imprinted onto the second surface 101b with the same pressing action used to weld the brazing sheet 601 to the brazing-ready cable connector 600.

[0112] The inventors have recognized that this second knurled pattern is particularly advantageous for brazable-ready cable connectors 600, which are brazed to a workpiece using a brazing gun 301 in which electrode 307 functions as the positive electrode (i.e., as shown in Figure 4a). When using such a brazing gun 301, the inventors have found that carbon powder (i.e., ions) is released from the carbon electrode 307 during the brazing process. This carbon powder deposits on the second surface 101b of the plate portion, forming a flaky structure. The flaky structure peels off (e.g., detaches from the surface) when a sufficient amount of carbon powder has accumulated on it. In doing so, the flaky structure can interfere with the electric arc 308, occasionally extinguishing it by short-circuiting. Thus, the brazing process cannot be completed and requires restarting. However, tests have shown that a second surface 101b imprinted with a knurled pattern 602 (e.g., a wavy surface) according to the embodiment reduces the risk of such flaky structure formation. Thus, the reliability of the brazing process can be improved. In this embodiment, the knurled pattern on the second surface is imprinted simultaneously with the ultrasonic welding process, thus eliminating the need for a separate manufacturing step.

[0113] Figure 8 shows a method for manufacturing a brazed-ready cable connector 600 according to an embodiment. This method may also be referred to as a method for preparing cable connectors for a brazing process.

[0114] In step 801, a cable connector 600 is provided. The cable connector 600 may be substantially identical to the cable connector 100 described in relation to Figure 1.

[0115] In step 803, a brazing sheet 601 is provided. The brazing sheet 601 includes a brazing material.

[0116] In step 805, the brazing sheet 601 is placed on the first surface 101a of the plate portion 101 of the cable connection component 600.

[0117] In step 807, the brazing sheet 601 is attached to the cable connector 600 by ultrasonic welding. Ultrasonic welding may be performed using an ultrasonic welding apparatus as described in relation to Figure 7.

[0118] The method may further include the step of imprinting a knurled pattern 602 onto the brazing sheet 601 and / or the first surface 101a of the plate portion 101 of the cable connector 600. Preferably, this step is performed simultaneously with step 807. For example, the knurled pattern 602 can be imprinted onto the brazing sheet 601 and / or the first surface 101a of the plate portion 101 of the cable connector 600 using a holding force.

[0119] The method may, alternatively or additionally, further include the step of imprinting a knurled pattern 602 onto the second surface 101b of the plate portion 101. Preferably, this step is performed concurrently with step 807. For example, the knurled pattern 602 can be imprinted onto the second surface 101b of the plate portion 101 using a holding force.

[0120] Figure 9 shows how to attach the cable connection component to the workpiece according to the embodiment.

[0121] In step 901, a brazed-ready cable connector 600 is manufactured according to the method shown in Figure 8.

[0122] In step 903, the brazed cable connector 600 is positioned relative to the workpiece.

[0123] In step 905, the electrode 307 of the brazing gun 301 is pressed against the brazed cable connector 600. The electrode 307 is pressed against the side of the brazed cable connector 600 that is opposite to the side on which the brazing sheet 601 is provided.

[0124] In step 907, current can flow from the power supply 303 of the brazing gun 301 through the electrode 307 to the brazed-ready cable connector 600. For example, current can be supplied by closing the switch 305.

[0125] In step 909, an electric arc 308 is generated by creating a gap that separates the electrode 307 from the brazed cable connector 600. The electric arc 308 is generated by a potential difference across the gap, which is maintained by the power supply 303 and control unit 304 of the brazing gun 301.

[0126] In step 911, the brazing sheet 601 is melted by heat transmitted through the plate portion 101 so that a bond is formed between the brazing-ready cable connector 600 and the workpiece. The melting of the brazing sheet 601 releases the ultrasonic welding, but the subsequent brazing joint forms a strong bond between the brazing-ready cable connector 600 and the workpiece. While re-brazing a joint is generally not advisable, when a strong bond is desired, the inventors have found that the brazing process according to Figure 9 allows for the complete melting of the ultrasonic weld, which does not adversely affect the strength of the subsequent brazed joint.

[0127] Figures 3 to 9 show cable connection components in the form of cable shoes (shown in Figures 1a to 1d), but it will be understood that embodiments may include other arbitrary cable connection components, such as cable connectors, as shown in Figures 1e to 1f.

[0128] Throughout this specification, the word “can” is used in a permissive sense (i.e., to have the possibility of doing something) rather than in an obligatory sense (i.e., to have to do something).

[0129] Throughout this specification, the words “comprise,” “include,” and their variations, such as “comprising,” “comprises,” “including,” and “includes,” do not preclude other elements or steps.

[0130] Where used throughout this specification, the singular forms “a,” “an,” and “it” include the plural form unless explicitly indicated otherwise. Thus, regardless of the use of other terms and expressions for one or more elements, such as “one or more” or “at least one,” a reference to an element, for example, “one,” includes a combination of two or more elements.

[0131] The term "or" is not exclusive unless otherwise indicated; that is, it encompasses both "and" and "or." For example, the feature "A or B" includes the features of "A," the features of "B," and the features of "A and B."

[0132] Unless otherwise indicated, the statement that one value or action "based on" and / or "dependent" another condition or value or action includes both cases where the condition or value or action is the sole factor, and cases where the condition or value or action is one of several factors.

[0133] Unless otherwise indicated, the phrase "each" case of several sets having certain properties should not be interpreted as excluding cases where several other otherwise identical or similar members of a larger set do not possess those properties; in other words, "each" does not necessarily mean each all.

Claims

1. A brazable-ready cable connector made of conductive material for attaching a cable to a workpiece, wherein the brazable-ready cable connector is A plate portion having a first surface for attachment to the workpiece, A cable receiving section for receiving cables, A sheet of brazing material provided on the first surface of the plate portion and Equipped with, A brazed cable connector component in which the sheet of brazing material is attached to the first surface by ultrasonic welding.

2. The brazed cable connector according to claim 1, wherein the brazing material contains silver.

3. The brazed cable connector according to claim 1 or 2, wherein the sheet of brazing material is in direct contact with the first surface of the plate portion.

4. The brazable ready cable connector according to any one of claims 1 to 3, wherein the ultrasonic welding includes a plurality of ultrasonic spot welds that form a first knurled pattern on the sheet of brazing material.

5. The brazable-ready cable connector according to any one of claims 1 to 4, wherein the first surface comprises a second knurled pattern.

6. A brazable-ready cable connector according to any one of claims 1 to 5, wherein the second surface of the plate portion opposite to the first surface is provided with a third knurled pattern.

7. A method for manufacturing brazed-ready cable connectors, wherein the method is The steps include providing a cable connection component comprising a plate portion and a cable receiving portion, A step of providing a sheet of brazing material, The steps include: placing the sheet of brazing material on the first surface of the plate portion; The steps include: ultrasonically welding the sheet of brazing material to the first surface using an ultrasonic welding device so as to attach the sheet of brazing material to the first surface; Methods that include...

8. The method according to claim 7, wherein the brazing material contains silver.

9. The method according to claim 7 or 8, wherein the step of ultrasonic welding includes performing a plurality of ultrasonic spot welds.

10. The method according to claim 9, further comprising the step of imprinting a first knurled pattern onto a sheet of brazing material by the plurality of ultrasonic spot welding.

11. The method according to claim 9 or 10, further comprising the step of imprinting a second knurled pattern on the first surface by the plurality of ultrasonic spot welding.

12. The method according to any one of claims 7 to 11, wherein the ultrasonic welding step includes the step of applying a holding force to the cable connection component with the ultrasonic welding apparatus, and the step of imprinting a third knurled pattern on the second surface of the plate portion opposite to the first surface by the holding force.

13. The method according to claim 12, wherein the steps of ultrasonic welding and imprinting on the second surface are performed in a single press operation.

14. A method for brazing a cable shoe to a workpiece, wherein the method is A step of manufacturing a brazing-ready cable connector component according to the method described in any one of claims 7 to 13, The steps include: positioning the brazing-prepared cable connector on the workpiece to bring the sheet of brazing material of the brazing-prepared cable connector into contact with the workpiece; The steps include pressing the electrode of the brazing gun against the brazed cable connection component, A step that enables current to flow from the power supply of the brazing gun through the electrodes to the brazed cable connection component, The steps include generating an electric arc by forming a gap between the electrode and the brazed cable connection part, The steps include: melting the sheet of brazing material by heat transmitted through the cable connection component to form a bond between the brazed cable connection component and the workpiece; Methods that include...

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