Flat Cable Riser Connection for Low-Resistance Dissimilar Joining
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Solution Overview
Problem
Existing methods for connecting flat metal cables to other cables are inefficient due to the formation of brittle intermetallics and increased electrical resistance, particularly when joining dissimilar materials like copper and aluminum, and the challenge of accommodating the space constraints in vehicles while maintaining high conductivity and mechanical properties.
Innovation Solution
A flat metal cable with a hollow riser extending from its surface, made through reversed extrusion, allows for a low-interface connection by housing a second metal cable and using friction welding to maintain conductivity and mechanical integrity, with an optional polymer coating for isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dissimilar metal welding (copper to aluminum) is used to connect cables, then electrical connection is achieved, but brittle intermetallics form and weaken the joint
Solution Approach 1:
The patent introduces an intermediate layer of pure aluminum between the copper contact and the aluminum cable. This intermediate layer acts as a mediator that prevents direct dissimilar metal welding, thereby avoiding the formation of brittle intermetallics while still enabling electrical connection. The pure aluminum layer bonds to the copper contact and provides a bonding surface for the aluminum cable strands.
Solution Approach 2:
The connection structure is segmented into distinct zones: the copper contact, the intermediate pure aluminum layer, and the aluminum cable strands. This segmentation allows each material to perform its specific function without direct contact between dissimilar metals, preventing intermetallic formation while maintaining electrical conductivity and mechanical strength.
2Ease of operation
If multiple interfaces are used in cable connections, then connection flexibility is improved, but electrical resistance increases
Solution Approach 1:
The patent merges the cable holder function and the electrical connection function into a single integrated component. The cable holder is formed as one piece with the bonding surface, eliminating the interface between separate holding and bonding components. This reduces the number of interfaces in the electrical path, thereby reducing electrical resistance while maintaining connection flexibility.
3Weight of moving object
If flat cables are used to save space, then vehicle weight and space consumption are reduced, but joining capability to other cables becomes difficult
Solution Approach 1:
The flat cable is designed with local quality variations: the main body remains flat for space efficiency, while the end portion features a raised bonding surface with increased thickness and embedded strands. This localized structural modification enables welding capability at the connection point without compromising the space-saving flat profile of the cable body, thus maintaining both weight advantage and joining capability.
4Weight of moving object
If aluminum cable is used instead of copper, then weight is reduced and fuel consumption decreases, but oxide formation on surface occurs and welding becomes difficult
Solution Approach 1:
The aluminum cable is designed with strands embedded in the bonding surface before the welding process. This preliminary arrangement of strands exposes fresh aluminum material at the bonding surface, removing the protective oxide layer that forms on aluminum. The embedded strands create immediate welding capability without requiring special oxide removal procedures during the welding 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 efficient joining of flat metal cables with minimal interfaces and process steps, reducing electrical resistance and maintaining mechanical properties, while accommodating space constraints and harsh environmental conditions.
Implementation Method 1
The riser may be welded onto the cable, or attached in other suitable manner, or the flat cable with a hollow riser extending from one of the flat surfaces may be made using reversed extrusion.
Implementation Method 2
the flat cable with a hollow riser extending from one of the flat surfaces may be made using reversed extrusion
Data Source
AI summary
The present invention relates to a first metal cable (1) having a flat upper (A) and a flat lower (B) surface, comprising at least one hollow riser (2) extending approximately 90 degrees from one of the flat surfaces of the first metal cable, the hollow riser being 5 configured to house an end of a second metal cable (3). A connected structure comprising a first metal cable wherein a second metal cable is inserted into the hollow riser (2) of the first metal cable and joined with the first metal cable. it also relates to a method of making a connected structure, joining a first metal cable to a second metal cable by friction welding the second metal cable (3) to the first metal cable by 10 contacting a rotating tool (4) with the lower surface of the first metal cable in the area underneath the hollow riser.