Method for simultaneous resistance brazing of adjacent conductor joints

• US 7,256,364 B2
• Filed: 12/21/2004
• Issued: 08/14/2007
• Est. Priority Date: 12/21/2004
• Status: Expired due to Fees

• Current Assignee: BorgWarner Incorporated
• Original Assignee: Remy International Incorporated (BorgWarner Incorporated)
• Inventors: Congdon, Christopher, Gentry, Ronald, Van Sickle, Richard A.
• Primary Examiner(s): Shaw; Clifford C.
• Application Number:
  US11/018,652
• Publication Number:
  US 20060131279A1
• Time in Patent Office: 966 Days
• Field of Search: 219/85.14, 219/85.15, 219/85.18, 219/56.1, 219/56.22, 298/50
• US Class Current: 219/85.15
• CPC Class Codes: B23K 1/0004 Resistance soldering
• CPC Class Codes: B23K 2101/38 Conductors
• CPC Class Codes: H02K 15/0081 for form-wound windings

Abstract

A method for simultaneously brazing adjacent conductor joints comprises the steps of arranging at least two pair of conductor joints in a row placing a brazing compound between the pairs of joints desired to be electrically connected placing a conductive spacer between the pairs not to be brazed and passing an electrical current through the row of conductors until the brazing compound melts joining the conductor joints. The spacer can then be removed thereby maintaining the proper spacing between the pairs of brazed conductor joints. The multiple rows of conductor joints can be arranged adjacent one another so that they can be moved between brazing electrodes sequentially thereby allowing a continuous brazing operation of multiple rows of conductor joints. The brazing compound may be a continuous ribbon of brazing compound which extends between the multiple rows of conductor joints.

Claims

1. A method of simultaneously brazing adjacent conductor joints comprising the steps of:

arranging at least a first pair and a second pair of conductor joints in a row, said first pair of conductor joints comprising a first conductor end portion and a second conductor end portion, and said second pair of conductor joints comprising a third conductor end portion and a forth conductor end portion;

placing a brazing compound between the first and second end portions of the first pair conductor joints and between the third and fourth end portions of the second pair of conductor joints;

placing a conductive spacer between the second end portion of the first pair of conductor joints and the third end portion of the second pair of conductor joints;

passing electrical current through the row of the first pair of conductor joints, the conductive spacer and the second pair of conductor joints to cause the brazing compound to melt and braze the first and second end portions together and the third and fourth end portions together;

removing the spacer.

2. A method as claimed in claim 1, wherein the step of passing electrical current comprises the additional steps of:

placing a first electrode next to the first end portion of the first pair of conductor joints;

placing a second electrode next to the fourth end portion of the second pair of conductor joints;

pressing the first and second electrodes toward one another to form electrical contact with the row; and

applying electrical potential across the first and second electrodes to cause electrical current to flow through the row.

3. A method as claimed in claim 1, wherein the step of placing a conductive spacer comprises placing a copper brace dimensioned to maintain the normal spacing between the second end portion of the first pair of conductor joints and the third end portion of the second pair of conductor joints.

4. A method of brazing adjacent conductor joints comprising the steps of:

arranging at least a first and a second pair of conductor joints in a first row, said first pair of joints comprising a first conductor end portion and a second conductor end portion, and said second pair of joints comprising a third conductor end portion and a forth conductor end portion;

arranging at least a third and a fourth pair of conductor joints in a second row spaced apart and adjacent the first row, said third pair of joints comprising a first conductor end portion and a second conductor end portion, and said fourth pair of joints comprising a third conductor end portion and a forth conductor end portion;

placing a brazing compound between the first and second end portions of the first pair and third pair of conductor joints and between the third and fourth end portions of the second pair and fourth pair of conductor joints;

placing a conductive spacer between the second end portion of the first pair of conductor joints and the third end portion of the second pair of conductor joints and between second end portion of the third pair of conductor joints and the third end portion of the fourth pair of conductor joints;

sequentially passing electrical current first through the first row of the first pair of conductor joints, the conductive spacer and the second pair of conductor joints so that the brazing compound melts to braze the first and second end portions of the first pair together and the third and fourth end portions of the second pair together, and next passing electrical current through the second row of the third pair of conductor joints the conductive spacer and the fourth pair of conductor joints to cause the brazing compound to melt to braze the first and second end portions of the third pair together and the third and fourth end portions of the fourth pair together.

5. A method as claimed in claim 4, wherein the step of placing a brazing compound comprises placing an elongated first ribbon of brazing compound between the respective first and second end portions in the first and second rows and an elongated second ribbon of brazing compound between the third and fourth end portions in the first and second rows.

6. A method as claimed in claim 5 where in a multiplicity of rows of conductor joints are arranged adjacent one another and the ribbon of brazing compound extend portions between the multiplicity of rows.

7. A method as claimed in claim 5, wherein the step of placing a conductive spacer comprises placing a copper brace dimensioned to maintain the normal spacing between the second end portion of the first and third pair of conductor joints and the third end portion of the second and fourth pair of conductor joints.

8. A method as claimed in claim 4, where in the step of sequentially passing electrical current comprise the additional steps of:

placing the first row of conductor joints between a first and a second electrode;

pressing the first and second electrodes toward one another to form electrical connection with the first row of electrical joints; and

applying electrical potential across the first and second electrodes until the brazing compound melts and brazed the respective end portions of the first row together;

moving the first and second electrodes away from the first row of conductor joints;

moving the second row of electrical joints between the first and second electrodes;

pressing the first and second electrodes toward one another to form electrical connection with the second row of electrical joints; and

applying electrical potential across the first and second electrodes until the brazing compound melts and brazed the respective end portions of the second row together.

9. A method as claimed in claim 4, wherein the step of placing a conductive spacer comprises placing copper braces dimensioned to maintain the normal spacing between the second end portions of the first and third pair of conductor joints and the third end portions of the second and fourth pair of conductor joints.

10. A method as claimed in claim 4 where in the step of placing a conductive spacer comprises the step of placing I-shaped members fabricated from an electrically conducting material and having a central portion dimensioned to slide between the respective second and third end portions to maintain the normal spacing therebetween, and having flanges at opposite ends of the central portion dimensioned to be wider than the space between the respective second and third end portions so that said I-shaped member will not slide out of the space between the respective second and third end portions.