AUTOMATION OF REACTION METALLURGICAL JOINING FOR COPPER CONDUCTORS
First Claim
1. A method of forming solid-state welds between surfaces of a plurality of pairs of adjacent copper conductors assembled on a stator core for an electric motor, the conductor pairs being spaced apart from neighboring conductor pairs, where one member of each copper conductor pair presents a first joining surface area facing a like-shaped second joining surface area of the second copper conductor, and the surface forming areas of the assembled copper conductors are accessible at a surface of the stator core;
- the method comprising;
inserting reactive metal between the joining surface areas of more than one pair of adjacent copper conductors;
using opposing electrode tools to apply pressure to each of the copper conductor pairs to either simultaneously or sequentially bring the facing joining surface areas of each pair of copper conductors into engagement with the reactive metal between them;
passing electric current through the engaged, conductor-reactive metal-conductor grouping to heat and melt the reactive metal for reaction with the copper conductor surfaces, to form reaction by-products;
expelling the reaction by-products from the facing, contacting joining surface areas of each of the copper conductor pairs to form a solid-state weld; and
stopping passage of the electric current.
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Accused Products
Abstract
Copper conductor members or other copper-based workpieces are welded using a suitable copper alloy material that is reactive with the joining surfaces of the copper members. The reactive metal material may be applied as a thin metal foil strip between assembled facing joining surfaces. The members are pressed together against the reactive material and electrical resistance heated in forming the weld. Practices are adapted for forming many such welds in the pairs of facing ends of conductor bars or wires assembled, for example, in slots in a stator for a vehicle traction motor. Practices are disclosed for shaping and automated placement of suitably sized and shaped foils of reactive metal. Practices are also disclosed for use of a resistance welding tool in aligning and heating the many pairs of conductors to be welded.
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Citations
23 Claims
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1. A method of forming solid-state welds between surfaces of a plurality of pairs of adjacent copper conductors assembled on a stator core for an electric motor, the conductor pairs being spaced apart from neighboring conductor pairs, where one member of each copper conductor pair presents a first joining surface area facing a like-shaped second joining surface area of the second copper conductor, and the surface forming areas of the assembled copper conductors are accessible at a surface of the stator core;
- the method comprising;
inserting reactive metal between the joining surface areas of more than one pair of adjacent copper conductors; using opposing electrode tools to apply pressure to each of the copper conductor pairs to either simultaneously or sequentially bring the facing joining surface areas of each pair of copper conductors into engagement with the reactive metal between them; passing electric current through the engaged, conductor-reactive metal-conductor grouping to heat and melt the reactive metal for reaction with the copper conductor surfaces, to form reaction by-products; expelling the reaction by-products from the facing, contacting joining surface areas of each of the copper conductor pairs to form a solid-state weld; and stopping passage of the electric current. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
- the method comprising;
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22. A method of forming solid-state welds between surfaces of a plurality of pairs of adjacent copper conductors assembled on a stator core for an electric motor, the conductor pairs being spaced apart from neighboring conductor pairs, where one member of each copper conductor pair presents a first joining surface area facing a second joining surface area of the second copper conductor, and the surface facing areas of the assembled copper conductors being accessible at a surface of the stator core;
- the method comprising;
positioning a plurality of spaced apart reactive metal portions mounted on a support between the joining surface areas of a plurality of pairs of adjacent copper conductors; using opposing electrode tools to apply pressure to the copper conductor pairs and bring the facing joining surface areas of each pair of copper conductors into engagement with the foil portion between them; passing electric current through the engaged conductor-reactive metal-conductor group to heat and melt the interposed reactive metal foil for reaction with the copper conductor surfaces to form reaction by-products; expelling the reaction by-products from the facing, contacting joining surface areas of each of the copper conductor pairs to form a solid-state weld; stopping passage of the electric current; and removing the reactive metal support from the stator. - View Dependent Claims (23)
- the method comprising;
Specification