Copper-Aluminum Power Cable Joint With Oxidation-Resistant Butt Welding
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Solution Overview
Problem
The existing methods for joining copper and aluminum conductors in power cables face challenges due to differences in melting points and oxidation film formation, leading to reduced joining quality and increased costs with the use of dedicated sleeve members.
Innovation Solution
A joining structure where the end side surfaces of copper and aluminum conductors are processed to achieve a high space factor, followed by upset butt welding, and an O-ring is used to address diameter differences, enhancing the joining quality and reducing the number of processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is performed on copper stranded-wire conductor at high temperature, then joining between copper and aluminum conductors is achieved, but oxidation film forms on the copper conductor and weld quality deteriorates
Solution Approach 1:
The copper stranded-wire conductor is pre-coated with a zinc layer before welding. This preliminary protective coating prevents oxidation film formation during the high-temperature welding process, ensuring good weld quality without requiring complex welding environment controls
Solution Approach 2:
A zinc coating is applied as an intermediary layer on the copper conductor surface. This intermediate zinc layer acts as a barrier between the copper base metal and the oxidizing atmosphere during welding, preventing oxidation while allowing the welding process to proceed at high temperatures
2Reliability
If dedicated sleeve members are used for joining copper and aluminum conductors, then joining reliability is improved, but manufacturing cost increases
Solution Approach 1:
The invention extracts and removes the dedicated sleeve member from the joining system. By directly welding the copper and aluminum conductors together after zinc coating, the complex sleeve structure is eliminated, reducing manufacturing cost while maintaining joining reliability through the protected weld interface
Solution Approach 2:
Instead of using expensive dedicated sleeve members, the invention employs a simple zinc coating that can be applied through conventional electroplating or hot-dip methods. This inexpensive protective layer provides sufficient oxidation prevention during welding without requiring costly specialized joining components
3Reliability
If copper conductor is used instead of aluminum, then electrical conductivity and mechanical properties are improved, but material cost increases significantly
Solution Approach 1:
The invention applies zinc coating locally on the copper conductor surface at the joining zone only. This localized treatment provides oxidation protection where needed during welding, while the bulk of the conductor can use cost-effective aluminum material, achieving a balance between performance and cost
Solution Approach 2:
The invention creates a composite structure with a zinc-coated copper conductor joined to an aluminum conductor. This composite approach allows utilization of copper's superior electrical and mechanical properties at the critical joining interface while using cost-effective aluminum for the main conductor body, optimizing both performance and economics
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 method improves the joining reliability and quality of copper-aluminum conductor joints, reduces costs, and prevents oxidation film formation, while maintaining the benefits of both materials' conductivity and cost-effectiveness.
Implementation Method 1
the end side surface of the first conductor and an end side surface of the second conductor are joined to each other by welding
Data Source
AI summary
Disclosed are a joining structure of different kinds of conductors, a joining method of different kinds of conductors, and a joint of power cables capable of improving joining reliability of a junction of the different kinds of conductors.