Welded Conductor Assembly With Cyanoacrylate Layer for Corrosion Relief
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Solution Overview
Problem
Existing methods for welding ribbon cables to battery contacts in electric vehicles fail to provide effective corrosion protection and tension relief at the welding point, while also being costly and complex.
Innovation Solution
An electrical connection assembly using a thin layer of cyanoacrylate glue between conductors, which serves as both a corrosion protector and tension reliever, utilizing surface roughness matching and inhibiting hardening agents to optimize the glue's properties, and employing affordable and easily handled materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cyanoacrylate glue is applied between conductors for temporary fixation during welding, then the conductors are easily joined, but the glue provides no corrosion protection or tension relief
Solution Approach 1:
The patent applies multi-functionality by enabling cyanoacrylate glue to perform three functions simultaneously: temporary fixation during welding, corrosion protection at the welding point, and tension relief. This transforms a single-function adhesive into a multi-functional component that addresses multiple technical requirements in the electrical connection assembly.
2Reliability
If a thick layer of cyanoacrylate glue is applied between conductors, then corrosion protection and tension relief are improved, but electrical contact resistance increases
Solution Approach 1:
The patent applies local quality by creating different glue layer thicknesses at different locations. A thin glue layer (first thickness) is maintained at the welding point area to ensure low contact resistance and good electrical conductivity, while a thicker glue layer (second thickness) is applied in surrounding areas to provide adequate corrosion protection and tension relief. This spatial variation in glue layer properties resolves the contradiction between protection and conductivity.
3Productivity
If conventional welding methods are used without additional protection, then the manufacturing process is simple, but the welding point lacks corrosion protection and tension relief
Solution Approach 1:
The patent merges the fixation function and protection function into a single cyanoacrylate glue application step. The glue serves both as a temporary fixture holder during welding and as a permanent protective layer at the welding point. This combination eliminates the need for separate protection layers or additional manufacturing steps, maintaining manufacturing simplicity while achieving reliable corrosion protection and tension relief.
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 cost-effective, simple method for welding conductors while ensuring low contact resistance, preventing electrochemical corrosion, and maintaining a thin glue layer for efficient electrical contact.
Implementation Method 1
at least one layer consisting of or comprising cyanoacrylate glue is located in at least one area between the two conductors
Implementation Method 2
the cyanoacrylate glue itself offers no corrosion protection nor any tension relieving function for the welding point
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to an electrical connection assembly (2), in particular for power electronics (1) for an electrically powered vehicle, and also to a method for the manufacture of such a connection assembly. Two conductors (4, 6) are connected to one another by a welding point (18). A layer (12) consisting of or comprising cyanoacrylate glue (14) is located between the two conductors (4, 6). The welding point (18) is located preferably in the area (16). Further, at least one layer (20) of a material (22) which impedes or prevents the hardening of the cyanoacrylate glue (14) may be present in the area (16). The thickness of the layer (12) is preferably a maximum of double the surface roughness (R) of the surface (28). To obtain a predetermined surface roughness R, the area (16) can at least partially be provided with a roughening (24).