Conical Aluminum Connector Structure for Copper-Aluminum Joints
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Solution Overview
Problem
Existing copper-aluminum joints in electrical connections for automobiles face issues such as electrochemical corrosion, increased resistance, and potential fires due to direct contact, along with inefficiencies in processing and resource waste in current solutions.
Innovation Solution
An electric energy transmission aluminum part with a conical insertion hole and a heat-shrinkable tube is used to prevent insulation layer crimping and reduce interference, while a copper-aluminum joint is formed through friction or other welding methods, avoiding material waste and extending application range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper is used for electrical connections, then electrical conductivity and thermal conductivity are improved, but resource availability deteriorates due to copper shortage and rising costs
Solution Approach 1:
The patent changes the material parameter from copper to aluminum, utilizing aluminum's adequate electrical conductivity (second only to copper) and abundant availability (7.73% in Earth's crust vs. 0.01% for copper) to resolve the contradiction between maintaining electrical performance and ensuring resource sustainability
Solution Approach 2:
The patent adopts aluminum, a cheaper and more abundant material, as a substitute for expensive copper, making electrical connections more cost-effective and resource-sustainable while maintaining acceptable performance through proper design
2Quantity of substance
If aluminum replaces copper, then resource availability and cost are improved, but corrosion resistance deteriorates due to electrochemical corrosion when aluminum directly contacts copper
Solution Approach 1:
The patent introduces an intermediary aluminum oxide layer that forms naturally on aluminum surfaces, acting as a protective barrier that prevents direct contact between aluminum and copper, thereby eliminating electrochemical corrosion while maintaining the benefits of using aluminum
Solution Approach 2:
The patent converts the naturally occurring aluminum oxide layer, which might be seen as a surface defect, into a beneficial protective barrier that prevents corrosion, transforming a potential weakness into a strength for corrosion resistance
3Reliability
If aluminum tube crimps insulation layer, then connection sealing is improved, but manufacturing precision deteriorates due to increased resistance and local heating
Solution Approach 1:
The patent extracts the insulation layer from the crimping process entirely, allowing the aluminum tube to crimp only the conductor. This eliminates the problems of insulation layer deformation, increased resistance, and local heating while maintaining adequate sealing through the aluminum tube's own structure
4Reliability
If aluminum tube length is increased to crimp insulation layer, then connection sealing is improved, but adaptability deteriorates due to interference with mating end environment
Solution Approach 1:
The patent removes the insulation layer crimping function from the aluminum tube, allowing the tube length to be optimized for electrical connection purposes only. This improves adaptability and reduces interference with mating end environments while maintaining adequate sealing through alternative means
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 reduces the risk of electrochemical corrosion, minimizes resistance, and prevents breakdowns, while saving resources and processing time by eliminating the need for crimping the insulation layer and reducing material waste.
Implementation Method 1
connect the aluminum tube and the copper terminal by friction welding
Data Source
Figure 1~3
Figure 4~5
AI summary
An electric energy transmission aluminum part, an aluminum connector and a copper-aluminum joint. The electric energy transmission aluminum part includes an aluminum body (1) internally provided with a conical insertion hole (11) which penetrates through front and rear ends thereof. The conical insertion hole is provided with a maximum diameter end and a minimum diameter end. Both the aluminum connector and the copper-aluminum joint include the electric energy transmission aluminum part. The electric energy transmission aluminum part, the aluminum connector and the copper-aluminum joint not only avoid an insulation layer (3) from being crimped into a lead portion and increasing a resistance of the lead portion, but also prevent an indentation from being formed on the surface of the insulation layer (3) and causing breakdown, and further reduce an interference with a mating end environment, thus achieving a wide application range. In addition, the copper-aluminum joint can also save the processing working hours and resources.