Splice Connector for Fine Gauge Aluminum Wire Joints
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Solution Overview
Problem
Fine gauge aluminum wire used in electromagnetic coils is prone to work hardening and mechanical fatigue, leading to breakage and open circuit failures, especially when joined with dissimilar wires, and conventional soldering methods risk overheating and corrosion in high-temperature applications.
Innovation Solution
A specialized disparate wire splice connector with blind bores and a partitioning wall is used, filled with solder materials to electrically couple magnet wires and secondary wires, minimizing deformation and heat exposure, and embedded within an inorganic dielectric body to reduce mechanical stress and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimping is used to join fine gauge aluminum wire to dissimilar wires, then mechanical and electrical connection is achieved, but work hardening occurs causing wire breakage and connection failure
Solution Approach 1:
A dissimilar metal intermediate wire (such as copper or silver) is introduced between the fine gauge aluminum wire and the final connection point. This intermediate wire has different mechanical properties that reduce work hardening effects on the aluminum wire during crimping, while still providing reliable electrical and mechanical connection. The intermediate wire acts as a buffer that protects the aluminum wire from excessive deformation forces.
2Reliability
If soldering is used to join fine gauge aluminum wire, then deformation forces are avoided, but overheating and oxidation occur causing wire damage and increased electrical resistance
Solution Approach 1:
The soldering process is performed in an inert or protective atmosphere (such as nitrogen or argon gas environment) that prevents oxidation of the aluminum wire surface. This inert environment eliminates the formation of oxide layers that would increase electrical resistance and compromise connection reliability, while allowing the soldering process to proceed without excessive heating damage.
3Ease of manufacture
If conventional soldering is used in confined spaces, then wire connections can be made, but moisture at the interface accelerates corrosion and connection failure
Solution Approach 1:
Moisture and contaminants are extracted and removed from the soldering interface area before and during the soldering process. This may involve pre-cleaning the wire surfaces, using flux that draws moisture away from the joint, or designing the connector structure to prevent moisture accumulation at the critical wire-to-wire interface, thereby preventing corrosion while maintaining manufacturing feasibility.
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 solution provides a reliable, low-ohmic resistance, high-corrosion-resistant solder connection that minimizes work hardening and mechanical fatigue, enabling prolonged and reliable operation of electromagnetic coils in high-temperature environments exceeding 400°C.
Implementation Method 1
The splice connector is soldered to these wire segments to electrically couple the coiled magnet wire and the secondary wire through the splice connector
Data Source
AI summary
Embodiments of a method are provided for joining a secondary wire to a magnet wire, such as a fine gauge aluminum or silver wire. Further provided are embodiments of a disparate wire splice connector and embodiments of an electromagnetic coil assembly including such a splice connector. In one embodiment, the electromagnetic coil assembly includes disparate wire splice connector having a first blind bore and a second blind bore. A coiled magnet wire having a segment inserted into the first blind bore is soldered to the disparate wire splice connector. A secondary wire having a segment inserted into the second blind bore is also soldered to the disparate wire splice connector such that the secondary wire is electrically coupled to the coiled magnet wire through the disparate wire splice connector.