Copper-Aluminum Joint via Magnetic Induction Welding
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Solution Overview
Problem
Conventional crimping methods for connecting copper terminals and aluminum wires in wire harnesses lead to electrochemical reactions, reducing mechanical and electrical performance, and are limited by shape constraints and inability to meet industrial-grade requirements for electrical and mechanical performance.
Innovation Solution
A magnetic induction welding method with a copper terminal divided into a connecting and functional part, using a metal spacer layer between the aluminum wire and copper terminal to control the welding zone area and distance, ensuring a stable and efficient connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional crimping method is used to connect copper terminal and aluminum wire, then the connection can be made mechanically, but electrochemical reaction occurs between copper and aluminum leading to decreased mechanical and electrical performance
Solution Approach 1:
The patent introduces a magnetic field as an intermediary to mediate the connection between copper terminal and aluminum wire. Through magnetic induction welding, the magnetic field generates eddy currents that produce heat and electromagnetic forces, enabling metallurgical bonding without direct chemical contact between dissimilar metals, thereby preventing electrochemical corrosion while achieving reliable electrical and mechanical connection.
Solution Approach 2:
The patent replaces the conventional mechanical crimping system with a magnetic induction welding system. Instead of relying on mechanical deformation and contact pressure, the invention uses electromagnetic fields to generate controlled heating and bonding forces, transforming the connection mechanism from mechanical to electromagnetic, which eliminates the electrochemical reaction problem inherent in direct metal-to-metal contact.
2Adaptability or versatility
If existing electromagnetic welding method is used, then welding can be achieved, but it is only applicable to cylindrical terminals and cannot weld terminals of other shapes
Solution Approach 1:
The patent enhances the universality of the electromagnetic welding method by designing a flexible fixture system and adjustable magnetic coil configuration that can accommodate various terminal shapes including flat, arc-shaped, wing-shaped open, circular closed, and polygonal closed terminals. The method maintains reliable welding performance across different geometries through parameter optimization and adaptive positioning, making the process universally applicable to diverse terminal types in wire harness manufacturing.
3Reliability
If direct welding of copper terminal and aluminum wire is performed without controlled parameters, then connection can be made, but electrical and mechanical performances do not meet industrial-grade requirements
Solution Approach 1:
The patent achieves industrial-grade connection quality by systematically optimizing and controlling key welding parameters including magnetic field strength, pulse duration, coil-to-workpiece distance, and fixture positioning. Through parameter sensitivity analysis and experimental calibration, the invention establishes precise parameter windows that ensure consistent electrical conductivity and mechanical strength while maintaining production efficiency. The controlled parameter system, though complex, enables repeatable high-quality welds that meet stringent automotive industry standards.
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 method enhances electrical and mechanical performance, reduces electrochemical reactions, and meets industrial-grade requirements by creating a seamless connection with improved durability and safety, while also reducing manufacturing costs and environmental impact.
Implementation Method 1
a magnetic induction welding method with a copper terminal divided into a connecting and functional part
Implementation Method 2
The method enhances electrical and mechanical performance, reduces electrochemical reactions, and meets industrial-grade requirements by creating a seamless connection
Data Source
AI summary
A joint of a copper terminal and an aluminum wire, the copper terminal is divided into a connecting part and a functional part connected to the connecting part, and an aluminum wire core of the aluminum wire is connected to the connecting part of the copper terminal. Preferably, the aluminum wire core extends or does not extend to the functional part. The connecting part is a component of the copper terminal that is connected with the aluminum wire, and the functional part is a fixed area of the copper terminal that is configured to connect to a power consumption device.