Thermal Spray Electrical Lead Attachment for Heating Elements
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Solution Overview
Problem
Existing methods for attaching electrical conductors to surface elements require significant space and are costly, with limitations in temperature tolerance due to the use of soldering materials and large metal electrodes.
Innovation Solution
The method involves thermally spraying an attachment material onto the surface element and conductor, creating a thin, intimate contact layer that reduces space requirements and allows for high-temperature applications, or using ultrasonic welding for a more robust and space-efficient connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering procedures are used to attach connecting leads to contact points, then electrical connection is achieved, but the attachment requires significant space and incurs high production costs
Solution Approach 1:
The invention changes the attachment method from soldering to thermal spraying, fundamentally altering the physical and chemical parameters of the attachment process. This enables a thin, intimate connection with minimal material usage, reducing the space demand at contact points while maintaining reliable electrical connection
Solution Approach 2:
The invention replaces the mechanical soldering process with a thermal spraying process, substituting a mechanical/chemical joining method with a thermal deposition method. This substitution allows for precise material placement and creates a robust electrical connection with minimal space requirements
2Reliability
If soldering procedures are used to attach connecting leads to contact points, then electrical connection is achieved, but production costs are comparatively high
Solution Approach 1:
The invention changes the attachment method from soldering to thermal spraying, fundamentally altering the physical and chemical parameters of the attachment process. This enables a thin, intimate connection with minimal material usage, reducing the space demand at contact points while maintaining reliable electrical connection
Solution Approach 2:
The invention replaces the mechanical soldering process with a thermal spraying process, substituting a mechanical/chemical joining method with a thermal deposition method. This substitution allows for precise material placement and creates a robust electrical connection with minimal space requirements
3Reliability
If ordinary soldering materials are used for attachment, then electrical connection is achieved, but temperature tolerance is limited
Solution Approach 1:
The invention uses composite materials consisting of metal powder mixed with bonding agent material for thermal spraying. This composite approach creates an attachment material that combines the electrical conductivity of metal with the adhesive properties of the bonding agent, enabling high-temperature tolerance while maintaining reliable electrical connection
Solution Approach 2:
The invention changes the attachment method from soldering to thermal spraying, fundamentally altering the physical and chemical parameters of the attachment process. This enables a thin, intimate connection with minimal material usage, reducing the space demand at contact points while maintaining reliable electrical connection
4Reliability
If large metal bands or foils are used as electrodes, then acceptable transition resistance is achieved, but much space is needed in the region of contact points
Solution Approach 1:
The invention changes the attachment method from soldering to thermal spraying, fundamentally altering the physical and chemical parameters of the attachment process. This enables a thin, intimate connection with minimal material usage, reducing the space demand at contact points while maintaining reliable electrical connection
Solution Approach 2:
The invention uses composite materials consisting of metal powder mixed with bonding agent material for thermal spraying. This composite approach creates an attachment material that combines the electrical conductivity of metal with the adhesive properties of the bonding agent, enabling high-temperature tolerance while maintaining reliable electrical connection
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 results in a compact, cost-effective attachment with low transfer resistance, enhanced durability, and the ability to maintain low temperatures at the attachment point, extending the lifespan of the device.
Implementation Method 1
A. first an attachment region of the conductor is placed at least indirectly next to the surface element; B. then the attachment region which is placed at least indirectly to the surface element of the conductor and a directly next to the attachment region placed region of the surface element is thermally sprayed over with an attachment material
Implementation Method 2
Depending upon what kind of thermal spray procedure it can additionally lead to melting on the material of its electrical conductor within the attachment region and/or of the material at the exposed surface of the surface element
Implementation Method 3
relative to the second procedure it is suggested, that the attachment region to the contact points ought to be by means of ultrasonic welding
Data Source
AI summary
An apparatus and methods for attaching electrical leads (22, 24) to a heating layer (16) of a heater are provided. An attachment material (50) is thermally sprayed over cords (32) of the electrical leads (22, 24), which are in contact with the heating layer (16) over a contact area (20). The attachment material (50) and the heating layer 16 are further thermally sprayed with a layer (52), which is an isolating material. The thermal sprayed connection between the electrical leads (22, 24) and the heating layer (16) thus provides more intimate contact and an improved electrical connection.