Resistance Welding Conductor Unit Plated Layer Removal
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Solution Overview
Problem
Existing methods for connecting an element wire with a plated layer to a metal plate, such as soldering or caulking, result in low mechanical strength and increased electrical resistance, making them unsuitable for wiring harnesses in motor vehicles.
Innovation Solution
A resistance welding method that clamps the objects between electrodes and applies a welding current to melt the plated layer, removing it and allowing direct contact between the core member and base member, preventing intermetallic compound formation and maintaining mechanical strength while avoiding increased electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solder is used to connect the element wire and metal plate, then the objects are electrically connected, but the mechanical strength of the welded part is low and it easily separates
Solution Approach 1:
The invention extracts and removes the plated layer (solder) from the welding interface through resistance welding. By eliminating the solder layer that forms weak intermetallic compounds, the connection achieves both electrical conductivity and mechanical strength through direct metal-to-metal contact between the core member and base member.
Solution Approach 2:
The invention changes the physical state of the plated layer from solid to liquid through controlled heating during resistance welding. This parameter change allows the plated layer to be removed, enabling direct contact between the core member and base member while maintaining electrical connection.
2Reliability
If the object with plated layer is connected to another object, then connection is achieved, but the electrical resistance between objects increases
Solution Approach 1:
The invention extracts and removes the plated layer from the welding interface through resistance welding. By eliminating the plated layer that increases electrical resistance, the connection achieves low electrical resistance through direct metal-to-metal contact between the core member and base member.
3Stability of the object's composition
If the plated layer is present at the welding interface, then the core member is protected, but intermetallic compounds form and deteriorate mechanical strength
Solution Approach 1:
The invention performs preliminary protection of the core member by coating it with a plated layer before welding. Then during the welding process, the plated layer is selectively removed to prevent intermetallic compound formation. This preliminary action maintains both protection and mechanical strength.
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 method ensures a strong mechanical connection with minimal electrical resistance, suitable for constructing wiring harnesses for motor vehicles by eliminating intermetallic compounds and maintaining the integrity of the core member during welding.
Implementation Method 1
applying a welding current between the pair of the electrodes on a condition that the two objects are pressed to bring the two objects close to each other, so as to allow a contacting surface between the two objects to generate heat
Implementation Method 2
the contacting surface are allowed to generate heat to melt the plated layer, so as to weld the outer surface of the core member of said one of the two objects and a base member of another of the two objects together
Data Source
AI summary
The resistance welding method of welding two objects together includes the steps of: clamping the objects between a pair of electrodes; and applying a current between the electrodes while the objects are pressed to bring them close to each other to allow a contacting surface between them to generate heat. One object includes a core member and a plated layer coating the core member and having a melting point lower than that of a metal constituting an outer surface of the core member. The objects are clamped between the electrodes and the contacting surface are allowed to generate heat to melt the plated layer to weld the outer surface of the core member of the one object and a base member of another object together. At least the outer surface of the core member and the base member are made of respective metals, between which no intermetallic compound is formed.