Flat Conductor Lap Joint Using Friction Stir Welding
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Solution Overview
Problem
Joining different metallic materials, particularly when aluminum is involved, results in problematic contact resistance and damage to previously formed intermetallic bonds during ultrasonic welding of electrical connections in flat conductors.
Innovation Solution
A connection arrangement using friction stir welding to form a continuous metallurgical bond between a flat conductor and connecting tabs, ensuring stable and permanent connections by plasticizing the materials and forming an intermetallic bond through a friction stir welding zone that extends along the longitudinal axis of the conductor, allowing multiple connections to be made simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to form intermetallic joints between different metals, then electrical connection quality is improved, but subsequent welding operations damage previously formed bonds
Solution Approach 1:
The patent segments the welding process into distinct spatial zones by positioning multiple terminal tabs at different locations along the flat conductor, allowing sequential welding without mutual interference. Each weld zone is separated from others, preventing vibration-induced damage to adjacent welds.
Solution Approach 2:
The patent applies preliminary protective measures by designing the welding fixture and tooling to isolate and dampen ultrasonic vibrations during each welding operation. This preliminary protection prevents vibration transmission to previously formed welds, maintaining their integrity throughout the multi-step process.
2Productivity
If multiple terminal tabs are welded sequentially along the flat conductor, then electrical connections are established, but welding vibrations compromise previous welds
Solution Approach 1:
The patent introduces intermediary elements including vibration-damping fixtures, clamping mechanisms, and tooling designs that act as mediators between the ultrasonic welding source and previously formed welds. These intermediaries absorb or isolate vibration energy, allowing multiple tabs to be welded sequentially without compromising bond integrity.
Solution Approach 2:
The patent implements beforehand cushioning by incorporating vibration-damping features and protective fixtures before the welding process begins. These measures cushion against the harmful effects of ultrasonic vibrations on previously formed welds, enabling high productivity while maintaining reliability.
3Adaptability or versatility
If different metallic materials are joined to create mixed-material flat conductors, then electrical power distribution capability is improved, but contact resistance at connection points increases
Solution Approach 1:
The patent applies parameter changes by optimizing the ultrasonic welding parameters (amplitude, pressure, time, temperature) specifically for joining different metallic materials. By adjusting these parameters, the process achieves low-contact-resistance intermetallic bonds between dissimilar metals, enabling versatile power distribution while maintaining connection reliability.
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 permanent intermetallic bond between different metallic materials, preventing damage to previous welds and ensuring low contact resistance, enabling multiple connections to be made efficiently and reliably.
Implementation Method 1
friction stir welding to form a continuous metallurgical bond between a flat conductor and connecting tabs
Implementation Method 2
plasticizing the materials and forming an intermetallic bond through a friction stir welding zone
Data Source
Figure 1a~1b
Figure 2a~2d
Figure 3
AI summary
The invention relates to a connection arrangement comprising a metal flat conductor having an at least quadrangular cross-sectional profile and at least two opposing first and second surfaces which extend in parallel with each other at least in part in the longitudinal direction, and at least two parts which are formed as connection lugs, are flat in the region of overlap, rest on the first surface with a lap joint and protrude beyond one or both long edges of the flat conductor, characterised in that a metal friction stir welding joining zone is formed starting from the second surface, extending through the flat conductor towards the first surface and protruding into the connection lugs.