Flat Conductor Lug Connection Using Friction Stir Weld Zones
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Solution Overview
Problem
Existing connection arrangements for flat electrical conductors, particularly in automotive applications, face challenges with transition resistance when connecting different metallic materials, such as aluminum and copper, and suffer from damage to previously welded joints during the ultrasonic welding process for multiple connections.
Innovation Solution
A connection arrangement utilizing a friction stir weld joint zone that extends continuously along the flat conductor and into the connection lugs, forming a permanently stable intermetallic bond between the flat conductor and the connection lugs, allowing multiple connections to be made in a single process without damaging previous joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to connect multiple connection lugs to a flat conductor, then intermetallic bonds are formed between dissimilar metals, but the welding vibrations damage previously produced welded joints
Solution Approach 1:
The flat conductor is divided into separate connection regions with spacing elements between them. Each connection region can be welded independently without affecting adjacent regions, as the spacing elements physically separate the connection zones and prevent vibration transmission between them.
Solution Approach 2:
Spacing elements are introduced as intermediary components between connection lugs. These elements act as mechanical buffers that absorb and isolate welding vibrations, preventing them from reaching previously welded joints while still allowing the flat conductor to provide electrical continuity.
2Area of stationary object
If connection lugs are arranged closely along the flat conductor to save space, then the connection arrangement becomes compact, but welding vibrations from one connection damage adjacent connections
Solution Approach 1:
The flat conductor surface is segmented into discrete connection zones separated by spacing elements. This segmentation allows compact arrangement of multiple connection lugs while maintaining sufficient isolation between them to prevent vibration damage, optimizing both space utilization and joint reliability.
Solution Approach 2:
Spacing elements are pre-positioned between connection lugs before welding begins. These elements provide beforehand cushioning by creating physical barriers that will absorb welding vibrations, protecting adjacent joints from damage even when connection lugs are arranged closely together.
3Adaptability or versatility
If different metallic materials are used for the flat conductor and connection lugs, then electrical outlets are realized along the flat conductor, but transition resistance at the connection point increases
Solution Approach 1:
The connection geometry parameters are optimized to compensate for material differences. By adjusting the overlap area, connection lug dimensions, and spacing element characteristics, the electrical transition between dissimilar metals achieves low resistance while maintaining mechanical stability.
Solution Approach 2:
The connection arrangement creates a composite structure combining different metallic materials (e.g., aluminum flat conductor with copper connection lugs). The spacing elements and optimized geometry facilitate effective electrical transition between these dissimilar materials, reducing transition resistance while maintaining adaptability for various electrical outlet configurations.
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 provides a stable and efficient method for connecting multiple lugs to a flat conductor, reducing transition resistance and preventing damage to previously welded joints, ensuring a homogeneous connection with low transition resistances between the lugs and cables.
Implementation Method 1
a friction stir weld joint zone (14) is formed which extends along a longitudinal axis (4) of the flat conductor (2) via the connection lugs (10)
Implementation Method 2
both the material of the flat conductor (2) and the material of the connection lugs (10) are plasticized
Data Source
AI summary
A connection arrangement comprising a metallic flat conductor having an at least quadrangular cross-sectional profile and at least two mutually opposing first and second surfaces extending at least partially parallel to one another in the longitudinal direction, at least two parts which are flat in the overlap region and which are formed as connecting lugs and which rest on the first surface with an overlap joint and project beyond one or both longitudinal edges of the flat conductor, characterized in that a metallic friction stir welded joint zone is formed starting from the second surface through the flat conductor towards the first surface and projecting into the connecting lugs.