Electrical Contact Assembly With Welded Interlocking Joint
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Solution Overview
Problem
Existing electrical contact assemblies face issues with delamination and settlement due to mechanical and thermal loading, leading to increased electrical resistance and safety concerns, particularly in switching elements where materials with high conductivity are often soft or expensive, and traditional bonding methods like soldering, welding, or riveting fail to provide a robust connection.
Innovation Solution
A method that combines material bonding and frictional or interlocking engagement between the contact and carrier in a single step, using resistance welding with a suitable electrode configuration and process parameters to create a robust connection, allowing for the use of materials like silver graphite and copper-based materials, and applying a thin bonding layer if necessary, to ensure a durable and safe electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering or welding is used to connect contact material to carrier, then electrical conductivity is improved, but delamination occurs under mechanical and thermal loading
Solution Approach 1:
The connection is divided into two distinct zones: a material bonding zone (soldering/welding) for electrical conductivity, and a mechanical engagement zone (interlocking/frictional) for structural strength. This segmentation allows each zone to optimize its function without compromising the other.
Solution Approach 2:
The patent combines material bonding and mechanical engagement methods into a single integrated connection system. The contact material support features both a bonding surface for soldering/welding and a mechanically engaged portion for interlocking, merging two connection approaches into one unified structure.
2Reliability
If contact material with high conductivity is used, then electrical performance is improved, but material hardness decreases making it soft
Solution Approach 1:
The contact material support is segmented into different functional zones: a contact area made of soft, highly conductive material (silver graphite) for electrical performance, and a mechanically engaged portion with higher strength properties for structural support. This allows each zone to have optimized properties for its specific function.
Solution Approach 2:
The contact material support uses composite construction, combining soft contact materials (silver graphite with 2-5% graphite content) with structurally stronger materials in different zones, achieving both high conductivity and adequate mechanical strength through material composition.
3Ease of manufacture
If conventional bonding methods are used, then manufacturing simplicity is maintained, but connection robustness deteriorates under thermal and mechanical loading
Solution Approach 1:
The patent merges material bonding and mechanical engagement into a single manufacturing step, where the contact material support is simultaneously bonded and mechanically engaged to the carrier. This integrated approach maintains manufacturing simplicity while achieving superior connection robustness.
Solution Approach 2:
The invention changes the connection parameters by introducing both chemical bonding (soldering/welding) and mechanical interlocking in one process, transforming the connection from a single-mode to a multi-mode system that withstands thermal and mechanical loading more effectively.
4Strength
If contact rivets are used for mechanical engagement, then connection strength is improved, but settlement occurs under mechanical and thermal loading
Solution Approach 1:
The patent combines material bonding and mechanical engagement in a single integrated connection, where the bonding zone prevents settlement by creating a permanent chemical bond, while the mechanical engagement zone provides structural strength. This dual-mode connection eliminates the settlement issue inherent in riveted connections.
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 produces a significantly more robust connection than riveted or soldered/welded assemblies, avoiding delamination and settlement issues, and maintaining high conductivity and temperature resistance, thus enhancing the safety and reliability of electrical contacts.
Implementation Method 1
A method for producing an electrical contact assembly by resistance welding a contact (21) to a contact carrier (10)
Implementation Method 2
a connection comprising frictional and interlocking engagement
Data Source
AI summary
A method for producing an electrical contact assembly includes. Providing a contact carrier of a first conductive material, the contact carrier having at least one depression or an aperture. Furthermore, a contact material support of a second conductive material is provided. This contact material support is pressed in the depression or the aperture while at the same time applying an electrical welding voltage to the contact material support and the contact carrier, a pressing-force/welding-current/time profile being chosen such that the contact carrier and the contact material support form a connection including interlocking and/or frictional engagement and a connection including material bonding in one working step.