Flexible Conductor Assembly With TIG-Welded Sheath for Low Resistance

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Solution Overview

Problem

Existing electrical conductors in high-temperature electrochemical systems, such as solid oxide electrolysis cells and fuel cells, suffer from significant ohmic losses and corrosion due to high temperatures and oxidizing environments, leading to inefficient energy transfer and system degradation.

Innovation Solution

A flexible electrical conductor assembly comprising a copper core protected by a stainless steel sheath, bonded with TIG welding and fillet-brazing, which reduces ohmic losses and prevents oxidation, allowing for efficient electrical connections in high-temperature environments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a copper core is used to reduce electrical resistance, then electrical conductivity is improved, but oxidation resistance deteriorates in high-temperature environments

Engineering Contradiction:

Improveelectrical resistanceVSAvoidoxidation resistance

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent employs a composite structure consisting of a copper core surrounded by a stainless steel sheath. The copper core provides excellent electrical conductivity with low electrical resistance, while the stainless steel sheath offers oxidation resistance in high-temperature environments. This composite material approach allows the conductor to simultaneously achieve both low energy loss and high reliability under elevated temperatures.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The copper core is nested within the stainless steel sheath, creating a concentric structure where the inner copper element benefits from the protective outer steel layer. This nesting arrangement ensures that the copper remains isolated from the oxidizing environment while maintaining electrical continuity through the assembly.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If a stainless steel sheath is added to protect the copper core, then oxidation resistance is improved, but device complexity increases

Engineering Contradiction:

Improveoxidation resistanceVSAvoidconductor structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The stainless steel sheath is designed as a thin-walled flexible tube that encompasses the copper core. This thin-film approach provides adequate oxidation protection without adding excessive structural complexity or weight. The flexibility of the sheath allows it to conform to the copper core while maintaining its protective function.

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If TIG welding is used to bond the sheath and connection strip, then bonding strength is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvebonding strengthVSAvoidmanufacturing process

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces mechanical fastening methods with TIG (Tungsten Inert Gas) welding to bond the stainless steel sheath to the connection strip. This substitution of mechanical joining with thermal welding creates a stronger, more reliable bond that can withstand high-temperature operating conditions, although it does increase manufacturing complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 significantly reduces electrical resistance by a factor of 10, enhancing energy efficiency and durability in high-temperature electrochemical systems, while maintaining flexibility and ease of assembly.

Implementation Method 1

the sheath and the first connection strip are bonded by TIG (Tungsten Inert Gas) welding

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

the conductive core and the first connection strip are bonded by fillet-brazing or soldering

Methodology Applied

Scientific EffectBrazing: Brazing

Data Source

PatentUS20250308724A1Flexible electrical conductor comprising elements connected to one another by TIG welding, and method for manufacturing such a flexible electrical conductor

Publication Date: 2025.10.02 COMMISSARIAT A LENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES

AI summary

A flexible electrical conductor including an assembly comprising a flexible conductive core made of a first metal material and a sheath covering the conductive core and made of a second metal material having an electrical resistivity higher than the electrical resistivity of the first metal material; a first connection strip formed at least in part by the second metal material and connected to a first end of the assembly, wherein, at the first end of the assembly, the sheath and the first connection strip are bonded by TIG welding, and the conductive core and the first connection strip are bonded by fillet-brazing or soldering.