Welding Terminal for Enameled Wires Reducing Impedance
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Solution Overview
Problem
Existing connection terminals for enameled wires in high-power applications suffer from insecure connections, high impedance, and galvanic corrosion due to traditional terminal-pressing methods, especially when using aluminum wires, leading to issues like pseudo welding, loose joints, and increased heat production.
Innovation Solution
A connection terminal design featuring an insulating plate with conducting plates secured by screws and thread-locking adhesive, allowing for secure enameled wire welding and external wire connection, with the option of copper, aluminum, or copper-aluminum transition plates to minimize impedance and prevent galvanic corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional terminal-pressing method is used to connect enameled wires, then the connection process is simple, but the connection security is poor and impedance is high
Solution Approach 1:
The patent replaces the traditional mechanical terminal-pressing connection method with a welding-based connection method. The conducting plate provides a welding surface that enables direct welding of enameled wires, transforming the connection mechanism from mechanical pressure to metallurgical bonding, thereby significantly improving connection security and reducing impedance while maintaining manufacturing simplicity through the integrated welding hole design.
2Quantity of substance
If aluminum wire is used to replace copper wire to reduce cost, then material cost is reduced, but welding difficulty increases and galvanic corrosion occurs
Solution Approach 1:
The conducting plate is designed with differentiated local properties: the welding surface is specifically treated or designed to be compatible with aluminum wire welding, while the external connection terminal can be made of copper or copper-alloy to prevent galvanic corrosion. This local quality differentiation allows the use of cost-effective aluminum wire while maintaining welding feasibility and preventing corrosion at the external connection points.
Solution Approach 2:
The conducting plate can be constructed as a composite structure or use transition materials (such as copper-aluminum transition plates mentioned in the patent) that combine the advantages of both aluminum and copper. This allows easy welding of aluminum wire while providing a copper interface for external connections, thereby reducing material cost without sacrificing manufacturability or preventing galvanic corrosion.
3Power
If multiple strands of aluminum wires are welded together, then current carrying capacity is increased, but welding quality deteriorates and impedance increases
Solution Approach 1:
The conducting plate is designed with multiple separate welding holes or a segmented welding surface that can accommodate multiple aluminum wire strands individually. Each strand can be welded separately or in small groups, ensuring proper welding quality and penetration for each strand while collectively achieving the required current carrying capacity. This segmented approach prevents welding defects that would occur if all strands were attempted to be welded as a single mass.
4Device complexity
If copper and aluminum wires are directly connected, then connection simplicity is maintained, but galvanic corrosion occurs and resistance increases over time
Solution Approach 1:
The conducting plate serves as an intermediary component between the aluminum wire and the external copper connection terminal. By using a transition plate or a plate with dual-material construction (aluminum welding surface and copper external terminal), the patent creates an intermediate interface that prevents direct galvanic contact between dissimilar metals, thereby eliminating galvanic corrosion while maintaining connection simplicity through the integrated plate structure.
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 terminal provides a secure, low-impedance connection that remains stable under high-frequency vibrations, reducing the risk of short circuits and maintaining electrical performance over time, even with multiple strands of wires.
Implementation Method 1
a fastening screw passes so as to secure the conducting plate onto the insulating plate
Implementation Method 2
A thread-locking adhesive is coated between the fastening screw and the insulating plate
Implementation Method 3
the other end is provided with at least one enameled wire welding hole for welding the enameled wire
Data Source
AI summary
A wire connecting terminal for enameled wires includes an insulating plate (2) and a pair of conductive bars (1) respectively fixed at two ends of the insulating plate. One end of the said bars is provided with a lead-wire welding hole (1a) for welding an external lead wire and the other end of the bars is provided with at least one enameled-wire welding hole (4a) for welding an enameled wire (4). The terminal has apparently low impedance, and the tensile strength of the welding points is more than 2000N. Because of being separated from the air, the welding points still remain excellent electrical performance and stability after a long period of operation. When operating in a high frequency vibration environment for a long time, the wire connecting terminal does not loose. The possibility of short circuit which is caused by two ends of a coil contacting directly with each other due to the deformation of the terminal thus can be prevented. The terminal is especially suitable for use in electrical components of high power and frequency.