Ultrasonic Welding Buffer for Aluminum Conductor Termination
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Solution Overview
Problem
Aluminum conductors tend to accumulate on ultrasonic welding tools during the welding process, leading to tool degradation and increased costs due to frequent replacements, and existing solutions either interfere with the welding process or require additional time and materials.
Innovation Solution
A system and method involving a thin sheet welding buffer made from materials like copper or brass, which fits within the terminal's conductor receiving area, preventing aluminum accumulation by creating a friction fit and allowing for seamless ultrasonic welding without the need for resin or shim materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to join aluminum conductors to terminals, then a reliable permanent connection is achieved, but aluminum accumulates on the welding tool causing degradation and increased costs
Solution Approach 1:
A copper buffer material is introduced as an intermediary between the aluminum conductor and the ultrasonic welding tool. The buffer material prevents direct contact between aluminum and the tool, eliminating aluminum accumulation while still enabling reliable electrical connection through the copper buffer to the terminal.
Solution Approach 2:
The copper buffer material is designed as a consumable component that is replaced periodically when degraded. This disposable approach is more economical than maintaining and cleaning the expensive ultrasonic welding tool, as the buffer can be easily replaced without specialized equipment or downtime.
2Loss of substance
If resin or shim materials are used to prevent aluminum accumulation, then tool degradation is reduced, but the welding process becomes more complex and time-consuming
Solution Approach 1:
The copper buffer material is made homogeneous in composition and properties, allowing it to be processed and installed using standard welding procedures without requiring different equipment or techniques. This simplicity contrasts with resin or shim materials that require specialized application processes.
Solution Approach 2:
The buffer material's physical parameters (conductivity, strength, dimensional stability) are optimized to enable direct ultrasonic welding without additional processing steps. The material is designed to be weldable in the same manner as standard copper conductors, maintaining process simplicity.
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
Prevents aluminum accumulation on the welding tool, reduces costs, and maintains a strong weld without interfering with the welding process or requiring additional time, as the buffer is inexpensive and easily integrated into the welding process.
Implementation Method 1
The terminal, the welding buffer and the aluminum conductor are ultrasonically welded together to form an integrated unit
Implementation Method 2
preventing aluminum accumulation by creating a friction fit
Data Source
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AI summary
A system and method for terminating a wire having an aluminum conductor includes a terminal having a conductor receiving area adapted to receive the aluminum conductor, and a welding buffer sized and shaped to fit within the conductor receiving area of the terminal with the aluminum conductor disposed between the welding buffer and the terminal. The terminal, the welding buffer and the aluminum conductor are ultrasonically welded together to form an integrated unit, such that the welding buffer forms a part of a finished terminated wire assembly.