Resistance Welding Flexible Electrical Lines to Rigid Components
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Solution Overview
Problem
Existing methods cannot effectively resistance weld flexible electrical lines with multiple metal wires to rigid components due to the inability to pressurize the wires adequately for a strong connection, leading to contact resistance issues.
Innovation Solution
The method involves inserting the free end of a flexible electrical line into a metal sleeve with a higher melting point than the components, pressing the second conductive component into the sleeve, and passing an electric current to fuse the ends together, ensuring a strong and low-resistance connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible electrical line with multiple wires is connected to a rigid component by conventional resistance welding, then the connection should have low contact resistance, but the wires cannot be adequately pressurized to achieve strong contact
Solution Approach 1:
A copper sleeve is introduced as an intermediary component between the flexible electrical line and the rigid component. The sleeve receives the flexible line, concentrates the pressing force, and transmits it uniformly to the wires, enabling adequate pressurization for resistance welding without damaging the flexible structure
Solution Approach 2:
The connection assembly uses composite materials with different properties: aluminum wires for flexibility and conductivity, copper sleeve for ductility and force distribution, and steel rigid component for structural strength. This composite structure enables both flexibility and effective pressurization
2Ease of manufacture
If aluminum is used for flexible electrical lines to achieve good price-performance ratio, then cost is reduced, but tensile strength is insufficient for reinforced applications
Solution Approach 1:
The electrical line uses a composite structure with aluminum wires for cost-effective conductivity and a chromium-nickel alloy reinforcement wire for high tensile strength. This combination maintains the price-performance advantage of aluminum while providing the necessary mechanical strength for reinforced applications
3Ease of operation
If a one-piece metal band or wire is used to provide rigidity for prefabricated electrical lines, then handling is simplified, but flexible areas cannot be achieved
Solution Approach 1:
The electrical line is designed with spatially varying properties: rigid sections made of one-piece metal band or wire for structural support and easy handling, and flexible sections made of multiple wires for adaptability. This local differentiation allows the line to be both easy to handle and flexible where needed
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 approach allows for the reliable connection of flexible electrical lines with multiple wires to rigid components by resistance welding, minimizing contact resistance and enhancing mechanical strength, while the sleeve protects the connection point from damage.
Implementation Method 1
electric current being passed through these two members, fusing their abutting ends together
Implementation Method 2
the ends of the metal components that lie against one another in a metal part surrounding the connection point Sleeve are connected to each other by resistance welding
Data Source
Figure 1~1C
Figure 2~2B
Figure 3~3A
AI summary
Method for connecting a first electrically conductive component in the form of a flexible electrical line (1) which has a plurality of wires (11) to a second electrically conductive metallic component, for example a second electrical line (2) or a connecting element. In this case, the free end of the flexible electrical line (1) is inserted into a sleeve (3) and is compressed with it and, furthermore, that end of the second electrically conductive component (2) which is associated with the flexible electrical line (1) is inserted into the free end of the sleeve (3) and is brought into contact with the flexible electrical line (I) and electric current is passed through these two components (1, 2) as a result of which their ends resting on one another are fused, with the sleeve (3) being produced from a metal which has a higher melting point than the metal(s) of the two components (1, 2) to be connected to one another.