Copper-Aluminum Connector Segmentation and Intermediary Design
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Solution Overview
Problem
Existing copper-aluminum connectors face issues with unstable pull-out force and mechanical strength due to deformation or cracking during friction welding, and they often require multiple connectors for high current demands, leading to space and cost inefficiencies.
Innovation Solution
A copper-aluminum connector design featuring a connecting part with a first connecting end for the copper terminal and a second connecting end for the aluminum wire, allowing for crimping or welding connections, which includes crimping terminals for enhanced stability and efficiency, and can be made of various materials for improved mechanical and electrical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction welding is used to connect copper terminal and aluminum tube, then connection is achieved, but aluminum tube and aluminum wire deform or crack due to poor mechanical strength and creep resistance
Solution Approach 1:
The connector is divided into distinct sections: an aluminum tube section for connecting to aluminum wire, a copper terminal section for connecting to copper busbar, and an intermediate transition section. This segmentation allows each part to be optimized for its specific function and connection method, avoiding the application of unsuitable welding stresses on aluminum components.
Solution Approach 2:
The patent introduces a copper transition plate as an intermediary component between the aluminum tube and copper terminal. This intermediary enables galvanic isolation, preventing direct contact between dissimilar metals, and allows for separate connection methods on each side, thereby eliminating the deformation and cracking issues caused by direct friction welding of aluminum parts.
2Power
If multiple copper-aluminum connectors are used for large current demand, then current capacity is met, but space and cost increase
Solution Approach 1:
The connector is designed with multi-functional capability to handle various connection configurations within a single integrated structure. The aluminum tube can accommodate multiple aluminum wires, and the copper terminal can connect to copper busbars of different sizes, allowing one connector to replace multiple traditional connectors for high current applications.
Solution Approach 2:
The patent utilizes spatial arrangement in multiple dimensions by allowing the aluminum tube to receive multiple aluminum wires from different directions and positions, and configuring the copper terminal to connect to busbars in various orientations. This dimensional utilization enables a single connector to achieve the current capacity of multiple connectors without increasing device complexity.
3Ease of manufacture
If aluminum wire is directly connected to copper terminal, then connection is simple, but galvanic reaction occurs due to electrode potential difference causing electrochemical corrosion
Solution Approach 1:
The patent introduces a copper transition plate as a galvanic intermediary between the aluminum wire and copper terminal. This intermediary layer prevents direct galvanic contact between dissimilar metals, eliminating the electrode potential difference that causes electrochemical corrosion, while maintaining a relatively simple connection structure.
Solution Approach 2:
The connector employs a composite structure combining aluminum tube, copper transition plate, and copper terminal in a multi-material assembly. This composite design allows each material to be used in its optimal environment, preventing galvanic corrosion while maintaining electrical conductivity and mechanical strength.
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 design increases pull-out force stability, improves assembly efficiency, reduces space and cost requirements, and ensures high electrical conductivity, making it suitable for large current demands while minimizing deformation risks.
Implementation Method 1
the end portion of the copper terminal is connected to the first connecting end by crimping
Implementation Method 2
the end portion of the copper terminal is connected to the first connecting end by welding
Implementation Method 3
the aluminum wire and the connecting part are connected to each other through friction welding
Data Source
AI summary
A copper-aluminum connector includes at least one copper terminal for connection to a power consumption device, and at least one aluminum wire for connection to an electrical circuit, wherein, the copper-aluminum connector further includes a connecting part, and the connecting part includes at least one first connecting end for connection to an end portion of the copper terminal and at least one second connecting end for connection to the aluminum wire.