Cable Contact Assembly Using Spot Friction Stir Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional welding processes are inadequate for metallurgical bonding of non-ferrous metals like copper or copper alloys with aluminum or aluminum alloys in high-voltage connectors, due to differing melting points, absorption spectra, and the need for expensive consumables, leading to insufficient mechanical strength and economic inefficiency.
Innovation Solution
A cable arrangement with a contact element laterally bonded to cable strands using a rotationally symmetrical welding tool, employing spot friction stir welding to create a metallurgical bond with a continuous region orthogonal to the cable strands, forming an intermetallic phase for enhanced mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding processes (laser welding, ultrasonic welding, thermal resistance welding) are used to bond non-ferrous metal contact elements with aluminum cable strands, then the bonding process can be performed, but the mechanical strength is insufficient and the process is economically inefficient due to expensive consumables and insufficient local focusing
Solution Approach 1:
The patent replaces conventional thermal welding processes (laser, ultrasonic, thermal resistance welding) with a mechanically driven welding process. A welding tool with a rotationally symmetrical cross-section is pressed against the contact element and cable strands, and rotated to generate friction heat locally, creating a metallurgical bond through mechanical action rather than conventional thermal or ultrasonic methods
Solution Approach 2:
The patent changes the fundamental welding parameters by using a rotationally symmetrical welding tool that generates heat through friction during rotation. The tool is pressed with a specific force against the contact element and cable strands, and rotated at controlled speed to create localized heat and metallurgical bonding, rather than using high-energy laser beams or ultrasonic vibrations
2Reliability
If welding processes are used to bond contact elements and cable strands, then material-bonded connections can be achieved, but the differing melting points and absorption spectra of the material pairing lead to insufficient local focusing and technically unsatisfactory results
Solution Approach 1:
The patent applies local quality by concentrating the welding action at the precise interface between the contact element and cable strands. The rotationally symmetrical welding tool, when pressed and rotated, generates heat and creates a metallurgical bond only at this specific location, ensuring proper material mixing and bonding without affecting surrounding areas
Solution Approach 2:
The patent replaces optical and thermal welding systems with a mechanically driven system. The welding tool is pressed with controlled force against the contact element and cable strands, and rotated to generate friction heat locally, creating a metallurgical bond through mechanical action rather than conventional thermal or ultrasonic methods
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
The solution provides a high-mechanical strength bond suitable for high-current applications, improving manufacturing efficiency and reducing costs by using aluminum or aluminum alloys for cable strands and copper or copper alloys for contact elements.
Implementation Method 1
spot friction stir welding
Implementation Method 2
The welding tool with a rotationally symmetrical cross-sectional geometry is pressed against a continuous area of the contact element and against the laterally adjacent cable strands and is rotated, so that the laterally adjacent cable strands and the contact element are metallurgically bonded to one another in a locally focused manner with high mechanical strength by the friction heat generated by the welding tool
Implementation Method 3
metallurgically bonded to one another in a locally focused manner with high mechanical strength
Implementation Method 4
forming an intermetallic phase for enhanced mechanical strength
Data Source
Figure 1A~1F
Figure 2A~2F
Figure 3A~7B
AI summary
The present invention relates to a cable assembly. The present invention further relates to a method for manufacturing a cable assembly. Finally, the present invention relates to a cable assembly device for manufacturing a cable assembly. A cable assembly (4) comprises a cable (3) with cable strands (2) and a contact element (1). A region (5) of the contact element (1), which is arranged laterally to the cable strands (2) relative to a longitudinal axis LKL of the cable strands (2), is metallurgically bonded to the adjacent cable strands (2). The region (5) has a circular transverse extent and a longitudinal extent that is oriented substantially orthogonal to a longitudinal axis LKL of the cable strands (2). The region (5) is a continuous region (5) of the contact element (1).