Multi-turn Wire Connection for Thermal Stress
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Solution Overview
Problem
Existing electrical connections between wires and stud-shaped metallic elements are prone to breaks due to tensile forces and thermal or mechanical stress, particularly at the connection point, leading to instability and reliability issues.
Innovation Solution
A connection method where the wire is wound in multiple turns around the metallic element, with alternating sections of insulation stripped and insulated wire, allowing for a large-area connection that can be soldered or welded, and incorporating a flexible turn to accommodate mechanical and thermal strain, using high-temperature-resistant insulation and conductive materials like copper or aluminum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional insulation-displacement/clamping connection or soldered/welded connection is used, then electrical connection is achieved, but wire breaks occur due to tensile forces from mechanical or thermal action
Solution Approach 1:
The connection wire is divided into multiple turns (at least two turns) around the connection element, creating segmented contact points distributed along the wire length. This segmentation distributes the tensile force across multiple contact zones rather than concentrating it at a single connection point, thereby preventing wire breaks while maintaining electrical connectivity.
Solution Approach 2:
The connection wire is arranged in multiple turns around the connection element, transitioning from a linear single-point connection to a multi-dimensional spiral configuration. This dimensional change allows the wire to accommodate thermal expansion and mechanical stress through rotational flexibility while maintaining stable electrical contact across multiple zones.
2Reliability
If the wire is wound in multiple turns around the connection element, then large-area connection and stability are improved, but the connection complexity increases
Solution Approach 1:
The multi-turn winding structure serves multiple functions simultaneously: it provides mechanical anchoring through friction, creates large-area electrical contact, accommodates thermal expansion, and absorbs mechanical stress. This multi-functionality achieves high reliability without requiring additional separate components or complex assembly procedures, thereby limiting the increase in overall device complexity.
3Reliability
If the wire is soldered or welded to the connection element, then low-resistance contact is achieved, but the connection becomes rigid and susceptible to thermal stress
Solution Approach 1:
Different sections of the connection wire have different properties: the portions in contact with the connection element are stripped of insulation to enable soldering or welding for low-resistance electrical contact, while the remaining insulated portions maintain flexibility and accommodate thermal stress. This local differentiation of properties allows the connection to simultaneously achieve excellent electrical conductivity and mechanical adaptability.
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 provides a stable and reliable electrical connection that withstands cyclic temperature stress and mechanical forces, maintaining electrical conductivity and flexibility, thus enhancing the overall stability and reliability of the connection.
Implementation Method 1
The insulation-stripped wire section is thus soldered or welded to the connection element
Implementation Method 2
The insulation-stripped wire section is thus soldered or welded to the connection element
Implementation Method 3
This is supported by a flexible or malleable insulation of the connection wire. By the incorporation of a flexible turn as a constituent of the connection, both thermal and mechanical strain, or tensile forces on the connection wire are compensated
Data Source
AI summary
A connection of a connection wire and a connection element are disclosed. In an embodiment a connection includes a connection wire having an insulation and a stud-shaped metallic connection element, wherein the connection wire is wound in a plurality of turns around the connection element, and wherein the turns include a first wire section, in which the connection wire is insulation-stripped, and a second wire section, in which the insulation is present.