Copper-Chromium Connecting Element for Low Resistance Fastening
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Solution Overview
Problem
Conductor-bar arrangements face high electrical transfer resistance due to surface roughness and soiling, which existing connecting elements, such as screws or nuts, fail to adequately address, especially when combining high mechanical strength with high electrical conductivity.
Innovation Solution
A connecting element, such as a screw or nut, is made from a material with a high mechanical tensile strength and high electrical conductivity, achieved through alloys like copper/chromium, copper/magnesium, or copper/niobium, with specific production methods including solution heat treatment and precipitation hardening, to minimize electrical transfer resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional materials (e.g., copper, steel) are used for the connecting element, then either high electrical conductivity is achieved but mechanical tensile strength is insufficient, or high mechanical strength is achieved but electrical conductivity deteriorates
Solution Approach 1:
The patent applies composite materials by combining copper (providing high electrical conductivity) with chromium or other alloying elements (providing mechanical strength). The connecting element is made from a composite material consisting of copper and 0.1-5.0 mass% chromium, which integrates the beneficial properties of both components into a single material system, resolving the contradiction between electrical conductivity and mechanical strength.
Solution Approach 2:
The patent changes the material parameters by precisely controlling the chromium content (0.1-5.0 mass%) and applying specific heat treatment parameters (solution treatment at 900-1100°C followed by precipitation hardening at 500-650°C). These parameter changes optimize the balance between electrical conductivity (≥60% IACS) and mechanical strength (tensile strength ≥500 MPa), resolving the contradiction by finding the optimal parameter range.
2Ease of manufacture
If surface roughness and soiling are present on conductor bars, then mechanical connection is easier but electrical transfer resistance increases
Solution Approach 1:
The connecting element acts as an intermediary component between the two conductor bars. By making the connecting element itself highly conductive through copper-chromium composite material, it mediates the electrical connection even when surface conditions of the conductor bars are not optimal, compensating for the harmful effects of surface roughness and soiling.
Solution Approach 2:
The patent changes the electrical conductivity parameter of the connecting element to be exceptionally high (≥60% IACS, preferably ≥80% IACS), which compensates for the increased contact resistance caused by surface roughness and soiling on the conductor bars, thereby maintaining low overall transfer resistance despite imperfect surface conditions.
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 effectively reduces electrical transfer resistance between conductor bars while maintaining sufficient mechanical strength, enabling efficient electrical and mechanical connections with enhanced conductivity.
Implementation Method 1
production methods including solution heat treatment and precipitation hardening
Implementation Method 2
production methods including solution heat treatment and precipitation hardening
Data Source
AI summary
The invention relates to a connecting element (4, 5), in particular a screw (4) or a nut (5), for mechanically connecting components (1, 2), the connecting element (4, 5) consisting at least partially of a material with a mechanical tensile strength of at least 350 MPa. According to the invention, the material of the connecting element (4, 4′, 5, 8) has an electrical conductivity of at least 50% IACS. The invention also relates to a corresponding production method for a connecting element (4, 5) of this type.