Friction Coated Electrical Connection Elements
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Solution Overview
Problem
Existing methods for producing electrical connection elements, particularly for connecting different metals like aluminum and copper, are complex and costly, making them unsuitable for small series production.
Innovation Solution
The use of friction coating as an alternative to conventional roll-bonding for applying a contact layer to the substrate, allowing for efficient and cost-effective connection of different metals by generating frictional heat to adhere the contact layer to the substrate, with the option of subsequent ultrasonic welding for secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If roll cladding is used to apply the contact layer to the substrate, then a metallurgical bond between different metals is achieved, but the manufacturing process becomes complex and costly
Solution Approach 1:
The invention changes the fundamental parameter of the bonding process from conventional roll cladding to friction coating. This involves changing the bonding mechanism from direct pressure and rolling to friction-induced heat and material transfer, thereby simplifying the manufacturing process while maintaining metallurgical bond quality
Solution Approach 2:
The invention replaces the mechanical roll cladding system with a friction coating system that uses a rotating rod or pin. This substitution changes the mechanical interaction from rolling compression to rotational friction, reducing process complexity while achieving the same metallurgical bonding objective
2Productivity
If roll cladding is used for applying the contact layer, then continuous coating is possible, but the process becomes too expensive for smaller production runs
Solution Approach 1:
The invention changes the production parameter from continuous roll cladding to discontinuous friction coating using a rotating rod. This allows flexibility in production volume, making the process economically viable for small series while maintaining the capability for continuous coating when needed
Solution Approach 2:
The invention introduces dynamic flexibility by allowing the friction coating process to operate in both continuous and discontinuous modes. The rotating rod can be applied continuously for high-volume production or individually for small batches, adapting to different production requirements and reducing cost for smaller runs
3Adaptability or versatility
If different metals are used for substrate and contact layer, then connection of different conductors is enabled, but contact corrosion occurs at the interface
Solution Approach 1:
The invention changes the interface parameter by creating a gradient structure through friction coating. The gradual transition of material composition at the interface reduces galvanic corrosion potential compared to sharp interfaces, while maintaining the ability to connect different metal conductors
Solution Approach 2:
The friction coating process creates a composite structure at the interface where the contact layer and substrate metals are metallurgically bonded with intermixed microstructure. This composite interface reduces corrosion by eliminating sharp galvanic boundaries and creating a transition zone with intermediate properties
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 method enables the production of cost-effective electrical connection elements suitable for connecting various metals, reducing contact corrosion and allowing for efficient production, even for small series, by applying a contact layer through friction coating and subsequent masking and coating processes.
Implementation Method 1
The rotation or oscillation of the rod, combined with its contact with the substrate, generates frictional heat
Implementation Method 2
a rotary welding process via a friction weld point
Implementation Method 3
subsequent ultrasonic welding for secure connections
Data Source
Figure 1~3
Figure 4
AI summary
Electrical connection element having a first flat part made of a metallic substrate and a metallic contact layer applied to one surface of the substrate. A reliable coating is possible through the substrate being friction coated with the contact layer.