Copper Disk Contact for Aluminum Conductors With Oxide-Removing Friction Aid
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Solution Overview
Problem
Aluminum conductors are not suitable for direct contacting with electrical components due to their physical properties, such as plastic flow behavior under pressure, making secure electrical connections challenging.
Innovation Solution
A contacting element configured as a copper disk with a conical or annular friction aid is applied to the aluminum conductor using welding methods like rotation, ultrasound, or resistance welding, allowing for secure friction-fit or interference-fit connections with electrical components, while the disk's shape and openings facilitate precise positioning and oxide removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If aluminum conductors are used for high current transmission, then current carrying capacity is improved, but direct contacting with electrical components becomes unreliable due to plastic flow behavior under pressure
Solution Approach 1:
A copper contacting element is introduced as an intermediary between the aluminum conductor and the electrical component. The copper element is welded to the aluminum conductor and provides a reliable friction-fit or interference-fit connection to the electrical component, thereby mediating the connection and eliminating the plastic flow issues of direct aluminum contact
2Reliability
If a conventional flange configuration is used for contacting, then electrical connection is achieved, but installation space and material usage increase
Solution Approach 1:
The contacting element transitions from a three-dimensional flange structure to a two-dimensional disk configuration. This dimensional reduction maintains the necessary contact surface area for reliable electrical connection while significantly reducing the volume and installation space requirements
3Reliability
If aluminum surface oxides are present during welding, then welding quality deteriorates, but oxide removal processes become more complex
Solution Approach 1:
The conical or annular friction aid structure on the contacting element is designed to actively press aluminum surface oxides into the center of the disk or outward during the welding process. This converts the harmful oxide layer into a manageable form that can be easily removed by subsequent boring or captured by an encircling collar, simplifying the overall oxide removal process
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 solution enables reliable and efficient contacting of aluminum conductors with electrical components, improving installation space usage, reducing material requirements, and ensuring precise and stable welding processes by managing oxide layers and tolerances.
Implementation Method 1
applied onto a surface, stripped of insulation, of the aluminum flat conductor by using a conventional welding method, such as, for example, rotation welding
Implementation Method 2
applied onto a surface, stripped of insulation, of the aluminum flat conductor by using a conventional welding method, such as, for example, rotation welding, ultrasound welding
Implementation Method 3
applied onto a surface, stripped of insulation, of the aluminum flat conductor by using a conventional welding method, such as, for example, rotation welding, ultrasound welding, or resistance welding
Implementation Method 4
Due to the friction aid, configured as conical or annular structure, of the disk, the advantage is achieved that during the connecting of the disk with the insulated flat conductor using a suitable welding process, the oxides of the aluminum surface of the flat conductor are either driven into the center of the disk
Data Source
AI summary
A device for the contacting of a conductor with an electrical component with a flat conductor made of aluminum includes a contacting element, which is connectable with the flat conductor in a material-bonded manner. The contacting element is formed of copper and configured as a disk, in which the disk includes a friction aid configured as a conical or annular structure on a first side, referred to as a joint side, and an outer contour, provided with at least one opening, on a second side opposite the joint side of the disk, for the receiving of the disk in an insertion contour corresponding to a welding tool.