Pure Copper Resistor Terminal Cold Pressing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for producing terminals for electric resistors using copper-tellurium alloy result in poor material economy due to significant material losses and high costs, necessitating the exploration of less valuable materials and more efficient processes.
Innovation Solution
A method involving the use of substantially pure copper, where pieces are prepared by longitudinal cold pressing to form thick and thin parts, followed by rolling operations to create a groove and taper the thin portion, reducing material waste and enabling effective joining with electric resistors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If copper-tellurium alloy is used for turning operations, then productivity and surface finish are improved, but material cost and material waste increase
Solution Approach 1:
The invention changes the material parameter from copper-tellurium alloy to substantially pure copper, and changes the processing method parameter from turning to cold pressing and rolling. This resolves the contradiction by achieving high productivity through cold-forming processes while eliminating the need for material removal, thus reducing swarf loss significantly.
Solution Approach 2:
The invention replaces the mechanical cutting system (turning operations) with a cold-forming mechanical system (cold pressing and rolling). This substitution eliminates material removal and swarf generation while maintaining high productivity through efficient plastic deformation processes.
2Ease of manufacture
If copper-tellurium alloy is used, then workability for turning is improved, but material cost increases
Solution Approach 1:
The invention changes the material composition parameter from copper-tellurium alloy to substantially pure copper, and changes the manufacturing process parameter from turning to cold pressing. Pure copper has excellent cold-formability, and the cold pressing process is simpler and more economical than turning operations with expensive alloy materials.
3Productivity
If turning operations are used on copper-tellurium alloy, then productivity is improved, but material economy deteriorates
Solution Approach 1:
The invention changes the processing method from turning (subtractive manufacturing) to cold pressing and rolling (formative manufacturing). This parameter change enables high productivity through efficient plastic deformation while achieving near-net-shape forming, thus dramatically improving material economy by eliminating swarf loss.
Solution Approach 2:
The invention replaces the turning mechanical system with cold-forming mechanical systems (cold pressing and rolling). This substitution transforms the manufacturing approach from material removal to material shaping, maintaining high productivity while achieving superior material economy.
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 allows for the production of terminals using less valuable materials while maintaining competitive productivity and finish quality, with significantly reduced swarf material and lower costs, utilizing high conductivity copper like CU-ETP1.
Implementation Method 1
reducing the thickness, by conveniently longitudinal cold pressing, of the piece 10 so as to obtain from it a thick part 11 and a thin part 12
Implementation Method 2
obtaining, by rolling, a groove 14, in a substantially central position of the thick part 11, tapering, by rolling, the thin portion 12
Data Source
Figure 1~4
Figure 5~6
AI summary
A method for manufacturing terminals for electric resistors, and the terminal obtained, which method consists in - preparing a piece (10) of substantially pure copper, - reducing the thickness, by cold pressing, of the piece (10) so as to obtain from it at least one thick part (11) and one thin part (12) designed to form the tip of an electrical terminal to be obtained, - obtaining, by rolling, a groove (14) which is central to the thick part (11), - tapering, by rolling, the thin portion (12).