Low resistance electric joint between conductive members, at least one member having an insulation coating thereon, and the method of making such joint

• US 4,317,277 A
• Filed: 07/16/1980
• Issued: 03/02/1982
• Est. Priority Date: 09/15/1978
• Status: Expired due to Term

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Bennett, Moreland P., Ettlinger, Louis F.
• Primary Examiner(s): Reynolds, B. A.
• Assistant Examiner(s): Tone, D. A.
• Application Number:
  US06/169,341
• Time in Patent Office: 594 Days
• Field of Search: 219/93, 219/92, 219/91.21, 219/94, 219/91.22, 174/94 R, 174/84 R, 174/84 L, 29/628, 29/860, 339/275 R, 339/275 T
• US Class Current: 29/860
• CPC Class Codes: B23K 11/163 Welding of coated materials
• CPC Class Codes: H01R 4/02 Soldered or welded connections H01R4/625, H01R4/723, H01R12/59 take precedence
• CPC Class Codes: H01R 4/026 comprising means for eliminating an insulative layer prior to soldering or welding
• CPC Class Codes: H01R 43/02 for soldered or welded connections
• CPC Class Codes: Y10T 29/49179 by metal fusion bonding
• CPC Class Codes: Y10T 29/49185 of terminal

Abstract

A sound, low resistance joint is provided between two electrically conductive members, at least one having a bonded insulation coating thereon. In one form of the method of the present invention, a continuous metallic penetrator having sharp edges or burrs, such as a brass screen, is interwoven about at least two bonded insulation coated conductive members. The coated conductive members and interwoven penetrator are placed in a conductive connector member having chamfered holes therein. Welding electrodes subject the connector member to heat and pressure with welding current flowing between the welding electrodes. At least some of the welding current flows through the continuous metallic penetrator before the penetrator makes electrical contact to the insulation coated conductive members. The penetrator becomes heated by thermal heat from the welding electroides and resistance heat as the welding current passes therethrough. Heat from the interwoven penetrator melts the bonded insulation from the surface of the coated conductive members, causing the insulation to vaporize. A metallurgical bond is formed between the conductive members, the connector member, and the interwoven penetrator. Excess metal from the conductive members and the metallic penetrator flows through the chamfered holes, forming rivets. Other embodiments are disclosed.

Claims

1. A method of joining at least two electrically conductive members which include bonded insulation thereon, comprising the steps of:

(a) interweaving a continuous conductor member about the insulated ends of said insulated conductive members;

(b) placing said insulated conductive members and said interwoven continuous conductor member into a highly conductive connector member with said continuous conductor member engaging the mating insulated surfaces of said insulated conductive members and the insulated surfaces of said insulated conductive members which mate with said highly conductive connector member, and

(c) subjecting said connector member to welding heat and pressure by welding electrodes with welding current flowing between said electrodes and spread across said interwoven conductor member, at least some of said welding current flowing through said continuous conductor member melting some of said bonded insulation before said continuous conductor member makes electrical contact with said conductive members wherein said bonded insulation is burned away and portions of said continuous conductor member, said conductive members, and said highly conductive connector member melt to form a metallurgical bond.

2. A method in accordance with claim 1 in which said continuous conductor member comprises a metallic penetrator having a plurality of sharp edges or burrs.

3. A method in accordance with claim 2 in which said metallic penetrator comprises a brass screen.

4. A method in accordance with claim 2 in which said metallic penetrator comprises a copper alloy sheet.

5. A method in accordance with claim 2 in which said metallic penetrator is of a material having about the same electrical conductivity and melting point as said conductive members and said connector member.

6. A method in accordance with claim 2 in which said bonded insulation comprises bonded enamel.

7. A method in accordance with claim 2 in which said conductive members comprise aluminum, said insulation coating comprises bonded enamel, said metallic penetrator comprises brass, and said connector member is selected from the group consisting of copper, aluminum, or high conductivity alloys of copper or aluminum.

8. A method of joining an electrical conductive member which includes bonded insulation thereon to a highly conductive connector member, comprising the steps of:

(a) wrapping a continuous conductor member about the insulated end of said insulated conductive member,

(b) placing said insulated conductive member and said continuous conductor member into said highly conductive connector member, and

(c) subjecting said highly conductive connector member to welding heat and pressure by welding electrodes with welding current flowing between said electrodes and spread across said wrapped conductor member, at least some of said welding current flowing through said continuous conductor member melting some of said bonded insulation before said continuous conductor member makes electrical contact with said conductive member wherein said bonded insulation is burned away and portions of said continuous conductor member, said conductive member, and said highly conductive connector member melt to form a metallurgical bond.

9. A method in accordance with claim 8 in which said continuous conductor member comprises a metallic penetrator having a plurality of sharp edges or burrs.

10. A method of joining at least two electrically conductive members at least one of which includes bonded insulation thereon, and at least one of which does not include bonded insulation thereon, comprising the steps of:

(a) wrapping a continuous conductor member about the insulated end of said insulated conductive member;

(b) placing said insulated conductive member, said non-insulated conductive member, and said wrapped continuous conductor member into a highly conductive connector member with said continuous conductor member engaging the mating surface between said insulated and non-insulated conductive members and the surfaces of said insulated conductive member which mate with said highly conductive connector member, and;

(c) subjecting said highly conductive connector member to welding heat and pressure by welding electrodes with welding current flowing between said electrodes and spread across said wrapped conductor member, at least some of said welding current flowing through said continuous conductor member melting some of said bonded insulation before said continuous conductor member makes electrical contact with said insulated conductive member wherein said bonded insulation is burned away and portions of said continuous conductor member, said insulated and non-insulated conductive member, and said highly conductive connector member melt to form a metallurgical bond.

11. A method in accordance with claim 10 in which said continuous conductor member comprises a metallic penetrator having a plurality of sharp edges or burrs.

12. A method in accordance with claim 11 in which said metallic penetrator comprises a brass screen.