Connection Assembly Material Bonding for Corrosion Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connection assemblies for small wire sizes and aluminum conductors face challenges in providing reliable and stable connections due to issues like relaxation at elevated temperatures and susceptibility to corrosion, which are not adequately addressed by prior methods such as laser beam welding and thermal contraction.
Innovation Solution
A method and tool for manufacturing a connection assembly where electrodes are located on the same deformation part, allowing for simultaneous plastic deformation and material bonding of faces using heating, either through electrical current or laser, to create a solder or welding bond, thereby enhancing the connection's stability and resistance to corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrodes are located on different deformation parts, then material bonding can be achieved, but device complexity increases and production is simplified less
Solution Approach 1:
The patent combines both electrodes onto a single deformation part instead of distributing them across multiple deformation parts. This merging of components reduces the overall device complexity and simplifies the manufacturing process while still achieving the desired material bonding between the two faces of the connection device.
2Reliability
If plastic deformation is applied to connection device, then good connection with low resistance is achieved, but connection reliability deteriorates due to relaxation at elevated temperatures
Solution Approach 1:
The patent changes the physical state of the connection interface by heating it to melt the coating layers, transforming the connection from a purely mechanical plastic deformation bond to a metallurgical bond. This parameter change (from room temperature deformation to elevated temperature melting) creates a more stable connection that resists relaxation at elevated temperatures during operation.
Solution Approach 2:
The patent employs composite material structure with coating layers (such as tin or zinc) on the connection device faces. These coating materials are specifically chosen to melt at relatively low temperatures and form strong metallurgical bonds with the conductor, creating a composite connection structure that combines the advantages of plastic deformation with the stability of soldered or welded joints.
3Strength
If coating material is melted for bonding, then strong material bond is achieved, but energy consumption increases
Solution Approach 1:
The patent replaces conventional mechanical heating methods with resistive heating by applying electrical current directly through the connection device and conductor. This substitution of heating mechanism allows for precise localized heating of only the coating layers at the bonding interface, minimizing energy consumption while achieving the necessary melting temperature for strong metallurgical bonds.
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 approach simplifies production, reduces the risk of connection relaxation at high temperatures, and improves the connection's resistance to corrosion by creating a strong, stable material bond that seals potential entry points for corrosive substances.
Implementation Method 1
heating, either through electrical current or laser
Implementation Method 2
heating, either through electrical current or laser
Implementation Method 3
create a solder or welding bond
Implementation Method 4
create a solder or welding bond
Implementation Method 5
improves the connection's resistance to corrosion by creating a strong, stable material bond that seals potential entry points for corrosive substances
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a connection assembly (1) comprising at least one conductor (2) and at least one connection device (3) which is plastically deformed about the conductor (2) to form two faces (7) which face each other. The invention further relates to a method of manufacturing such a connection assembly (1) and to a tool (10) for manufacturing such a connection assembly (1). The object of the invention is thus to provide a solution that allows to use such connection assemblies (1) in a wider size range and with different materials. This object is achieved by a connection assembly (1) in which the two faces (7) are connected to each other by a material bond (15). An inventive method includes the step of materially bonding the two adjacent faces (7) to each other. An inventive tool (10) comprises a bonding unit (14) for materially bonding the two faces (7) of the connection device (3) to each other.