Device and Method for Compact Embedded Wire Welding Using a Shape-Forming Electrode

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing date under 35 U.S.C. § 119(a)-(d) of European Patent Application No. 20202474.1, filed on Oct. 19, 2020.

FIELD OF THE INVENTION

The present invention relates to resistive welding of electrical cables and/or wires and, more particularly, to a device and method for creating a joint between electrical wires of different cross-sections and/or made of dissimilar materials, such as between multi-strand cables and solid core electrical wires, by resistance welding.

BACKGROUND

Resistance welding is commonly used for electrically interconnecting electrical cables and/or wires in a wide range of applications. In particular, electric cables/wires made of different materials or sizes are often interconnected by resistance welding, such as e.g. in automotive applications where the thin wiring of sensor devices needs to be electrically connected to thicker cables of on-board interfaces.

In the conventional resistance welding technique for creating a welded joint, two electrical cables and/or wires are disposed in an overlapping manner between welding electrodes which will apply a welding current sufficient to generate heat at the overlapping region (see FIG. 7). The generated heat should cause an at least partial melting of the overlapping wires at the contact region, thereby forming the welded joint. The welding electrodes are in general supplied with an appropriate welding current pulse using a welding power supply that allows controlling the current pulse depending on several parameters, such as material(s) and dimensions of the metallic components to be welded, and the intended welding quality. In order to improve the quality of the welded junction, the welding electrodes may apply a slight compression to the wires to be welded for reducing the contact resistance at the overlapping surfaces during the welding process.

One of the problems associated with the conventional technique for resistance welding of a multi-strand cable 10 to a single core wire 20 of a significantly smaller diameter is the difficulty in maintaining the position of the thinner wire 20 during welding, as illustrated in FIG. 7. In addition, due the large diameter discrepancy, the contact surfaces with the respective positive and negative welding electrodes, as represented by the arrows in FIG. 7, are not the same. This means that, when applying a welding current across the overlapped multi-strand cable 10 and solid core wire 20, there will be significant differences in the heat generated at each contact surface and consequently, the quality of the resultant joint will not be good.

In spite of a fine control of the welding parameters being possible, in general the quality of welded joints formed between a wire that is simply disposed on top of a much larger cable remains poor in situations where there is a significant difference between the cross-sections and/or materials of the wires to be welded. This is partially due to the difficulty in achieving a good relative positioning and contact of a thin wire over a cable of a much larger cross-section during the welding process, which results in several adverse effects on the mechanical strength and quality of the welding joint. For instance, the large variance in the relative positioning between wires leads to significant variations in the contact resistance between their contacting surfaces and, therefore, to poor melting of the respective metals at each side of the contact interface. This also leads to an intermetallic compound, which is necessary for ensuring a good quality of the welding, being created only at the (poorly) contacting surfaces.

The mechanical strength of welded joints obtained by conventional resistance welding is also generally characterized by a low peel force due to the poor encirclement of the interconnected wires, which implies welding longer segments in order to increase the joint mechanical stability. This is the case of welded joints obtained by hot staking of cooper strands with a Dumet wire of a Dumet-based thermistor, where the Dumet wire has only 30% of the cooper cable circumference. In addition, the oxidation of the Dumet wire and the fact that it cannot be pressed against the cooper stranded wire pose additional difficulties in obtaining a welded joint of good quality.

Other techniques used for interconnecting electrical cables and/or wires, such as crimping, have been considered for avoiding the above-mentioned shortcomings of conventional resistance welding. However, the space usually available for interconnecting wires in many applications, such as automotive applications, is in general limited which makes the use of crimping difficult or even impossible. Moreover, resistance welding is a simple and cost effective technique.

Thus, there is a need for a welding technique that allows forming welded electrical junctions of improved quality and mechanical stability, and in particular, for applications where electrical cables and/or wires having a significant disparity in the respective cross-sections and/or composing materials have to be interconnected in a simple, cost effective and reliable manner.

SUMMARY

An apparatus includes a set of pre-welding electrodes including a shape-forming electrode having a contact face. The contact face has a shape-forming structure shaping a cross-section of a first segment of a first wire with a pre-welding shape upon compression of the contact face against the first segment. The pre-welding shape has a reentrance accommodating a second segment of a second wire to be welded to the first wire.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of example with reference to the accompanying Figures, of which:

FIG. 1 is a schematic sectional view of a set of pre-welding electrodes according to an embodiment used for pre-shaping a first segment of a first wire with a pre-welding shape;

FIG. 2 is a schematic sectional view of the set of pre-welding electrodes of FIG. 1 applying a compression to the first segment of the first wire to form the pre-welding shape;

FIG. 3 is a schematic side view of a set of welding electrodes for performing a welding process with compaction according to an embodiment;

FIG. 4A is a schematic sectional view of a first sub-set of welding electrodes from the set of welding electrodes of FIG. 3 arranged at a first position about the pre-shaped first segment with an inserted second segment;

FIG. 4B is a schematic sectional view of the first sub-set of welding electrodes of FIG. 4A applying a pressure onto the first segment to enclose the second segment and changing the first segment into a welding shape;

FIG. 5A is a schematic sectional view of the first sub-set of welding electrodes of FIG. 4B during a process of welding with compaction with a welding current applied;

FIG. 5B is a schematic side view of the set of welding electrodes during the step of the process shown in FIG. 5A;

FIG. 6A is a sectional view of the first segment and the second segment at an end of the welding process with compaction performed with the welding electrodes shown in FIG. 3;

FIG. 6B is a side view of the first segment and the second segment in the state shown in FIG. 6A; and

FIG. 7 is a perspective view of a solid core electrical wire and a multi-strand cable, prior to welding, as used with a conventional resistance welding technique.

DETAILED DESCRIPTION OF THE EMBODIMENT(S)

The present invention will now be described hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. The accompanying drawings are incorporated into and form a part of the specification for the purpose of explaining the principles of the invention. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that the disclosure will be convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

A concept underlying a method of compact embedded wire welding of the present invention lies in improving the quality and stability of welded joints, namely, between multi-stranded cables and single core wires, by initially performing a pre-welding shaping process, in which a cross-section of a first segment of a first wire (normally the larger diameter wire) is compacted into a predetermined pre-welding shape that forms a reentrance for placing a second segment of a second wire to be welded to the first wire in a precise and stable position. In a subsequent step, the second segment is positioned in the reentrance of the pre-shaped cross-section of the first segment for initiating a welding process. During the welding process, the left and right borders of the reentrance formed in the pre-shaped cross-section of the first segment are first brought together such as to encircle the second segment cross-section, entirely or at least partially. The encirclement of the second segment, which has a smaller diameter, by the larger cable allows to achieve a good contact surface between both segments as well as between the larger cable and the welding electrodes, and therefore, a homogeneous distribution of welding currents across the first segment may be achieved during the subsequent welding process. This facilitates the formation of an intermetallic compound and improves melting of the first segment, which results in an improved quality and mechanical stability of the resultant joint.

Thus, the present invention makes possible to reduce or completely eliminate the negative effects of the conventional technique that are associated with the large positional variance and/or the discrepancy in the melting temperatures between the cables/wires to be welded by providing a welding technique that includes performing a pre-welding shaping process on one of the wires/cable to be welded, in an embodiment on the wire/cable having the larger cross section and/or which is easier to deform, prior to welding, such as to create a reentrance along a segment of the first wire for accurately positioning the second wire to be welded and attain similar contact surfaces and welding current densities during the final welding process.

FIGS. 1 and 2 illustrate a set of pre-welding electrodes 100 for performing a shape-forming process on a first segment 110, shown in FIG. 3, of a first wire 10 prior to welding the first wire 10 to a second wire 20 of smaller diameter. The set of pre-welding electrodes 100 may also be referred to as an apparatus. During the shape-forming process, a cross-section of the first segment 110 is shaped with a predetermined pre-welding shape that includes a reentrance 115 for subsequently accommodating a second segment 120 of the second wire 20 in an aligned position relative to the first segment 110.

In the embodiment shown in FIG. 1, the first wire 10 is a multi-strand cable with a circular cross-section before the shape-forming process. Multi-stranded cables are generally formed by a bundle of thin electrical wires, which are grouped together to form a cable of larger cross-section. Such multi-stranded cables are very flexible and can be easily deformed or compacted, prior to welding, into different shapes that are more favorable for positioning and maintaining the alignment of the second wire 20 of smaller diameter during a subsequent resistance welding process. The second wire 20, in an embodiment as shown in FIG. 3, is a single wire with a solid core, such as a Dumet wire. However, the second wire 20 may also be a multi-stranded wire of a smaller diameter than the first wire 10.

The set of pre-welding electrodes 100, shown in FIGS. 1 and 2, includes a shape-forming electrode 130 having a contact face 132 which is provided with a shape-forming structure adapted to transfer the desired pre-welding shape to the cross-section of the first segment 110, which in general has a circular cross-section such as shown in FIG. 1. The set of pre-welding electrodes 100 may also include a base electrode 140, onto which the first segment 110 of the multi-stranded cable 10 may be loaded prior to the shape-forming process and which is used for compressing the loaded multi-stranded cable 10 against the shape-forming electrode 130.

The desired pre-welding shape to be formed in the first segment 110 includes a longitudinal depression or reentrance 115, shown in FIG. 4A, that extends on the outer surface of the first segment 110 along a suitable length for subsequently accommodating and maintaining an end segment 120 of the second wire 20 to be welded to the first wire 10 in an accurate and stable position relative to the first segment 110 during a resistance welding process.

In order to form the reentrance 115 along the first wire segment 110 for positioning the second wire segment 120, the shape-forming electrode 130 is provided with a protrusion 134 on a contact face 132 of the shape-forming electrode 130, as shown in FIG. 1, that will come into contact with the first segment 110 during the pre-welding, shape-forming process. When the first segment 110 is pressed against the shape-forming electrode 130, for e.g. via the base electrode 140 positioned at the side opposed to the shape-forming electrode 130, the cross-section of the first segment 110 placed between the pre-welding electrodes 130, 140 is forced to bend from the left and right sides with respect to the protrusion 134, thereby forming a longitudinal reentrance or channel 115 along the outer surface of the first segment 110 for accommodating the second wire segment 120. The shape-forming structure at the contact face 132 of the shape-forming electrode 130, in an embodiment, is provided with a cavity or groove 136, on which the protrusion 134 is provided at an intermediate position on the bottom of the groove 136, so that the shape-forming structure is a W-shaped cavity suitable to receive the portions of the first segment 110 that are bent from the left and right sides of the elevation 134 under compression from the base electrode 140. As a result, the bent portions of first segment 110 may be easily molded into the pre-welding shape formed by the protrusion 134 and surfaces 138a, 138b of the W-shaped cavity and the wire strands 111 of the first segment 110 compacted against each other to form parallel ridges 118a and 118b on each side of the reentrance 115. The parallel ridges 118a and 118b not only facilitate the positioning of the second wire segment 120 onto the first segment 110 prior to welding but are also used for forming a welding shape for the subsequent resistance welding process, as it will be described later.

In the configuration shown in FIGS. 1 and 2, the contact face 132 has a cavity with W-shaped cross-section formed by the rounded surfaces 138a, 138b at the left and right sides of the protrusion 134. Moreover, the shape-forming electrode 130 and the W-shaped cavity on the contact face 132 have a sufficient length (i.e. in the longitudinal direction BB' of the first segment 110 which is transverse to the direction AA′ depicted in FIGS. 1 and 2) for forming a reentrance 115 along the first segment 110 with a length sufficient for inserting the second segment 120. On the other hand, the shape-forming structure in the contact face 132 may be designed with a profile other than the W-shape illustrated in FIGS. 1 and 2, depending on the desired pre-welding shape, to be transferred into the first segment cross-section by compaction against the shape-forming structure as described above.

The dimensions and relative size of the protrusion or elongation 134 and shape-forming groove 136 are selected depending on the diameter of the first and second wires 10, 20 to be welded. For instance, the protrusion 134 may have a height with respect to the bottom surfaces 138a, 138b of the groove 136 (i.e. in the AA′ direction) which is twice the diameter of the second wire 20. This allows forming parallel ridges 118a, 118b of a sufficient height for encircling the second wire 20 during the subsequent welding process, as it will be described later. The width of the elongation 134 along the direction CC' may be selected to be slightly larger than the diameter of the second wire 20, such that the reentrance 115 formed during the pre-welding process will have a sufficient size for accommodating the second wire 20. In the case of a Dumet wire, an elongation width equal to the diameter of the Dumet wire+0.05 mm may be used. The depth of the shape-forming groove 136, i.e. the depth of the surfaces 138a, 138b with respect to the edge of the contact face 132 of the shape-forming electrode 130 is equal to 75% of the diameter of the first wire 10 in an embodiment.

The first segment 110 may be compressed against the shape-forming structure by moving the shape-forming electrode 130 against the first segment 110 loaded into the base electrode 140 (or reversibly moving the base electrode 140 towards the shape-forming electrode 130) and applying a compression force sufficient for deforming and compacting the first segment 110 cross-section into the shape-forming structure for acquiring the desired pre-welding shape, as depicted in FIG. 2. The base electrode 140 then also functions as a compression electrode. The compression electrode 140 is designed such that the face that comes into contact with the first segment 110 during the pre-welding, shape-forming process, i.e. the compression face 142 shown in FIG. 1, has a flat surface oriented in a direction transverse to the direction AA′ along which pressure is applied against the shape-forming electrode 130. The area of the compression face 142 is dimensioned so as to allow the compression electrode 140 to enter partially through the upward overture of the shape forming groove 136 without touching the shape-forming electrode 130, thereby allowing a full compaction of the first segment 110 cross-section against the bottom 138a, 138b of the groove 136 and an integral transfer of the desired pre-welding shape into the first segment 110 without the compression electrode 140 entering into electrical contact with the shape-forming electrode 130.

In the embodiment shown in FIGS. 1 and 2, the compression electrode 140 has a flat surface 142 oriented in a direction transverse to the direction of applying pressure against the shape-forming electrode 130. Alternatively, a compression electrode 140 having a compression face with a profile that complements the shape of the groove 136 on the shape-forming electrode 130 may be used so as to distribute the pressure applied by the compression electrode 140 more evenly across the diameter of the first segment 110 and/or improve the compaction of the multi-stranded wire 10.

The shape-forming electrode 130 and the compression electrode 140 (or vice-versa) may be made of an electrically conductive material so as to additionally function as anode and cathode electrodes, respectively. In this case, during the pre-welding shape-forming process, an electrical potential difference may be applied by the shape-forming electrode 130 and the base electrode 140 across the cross-section of the first segment 110 placed in-between so as to cause a current of a suitable intensity to pass across the first segment 110 cross-section for softening the first segment strands 111 and consequently, improve flexibility of the first segment 110 during compaction and achieve a better definition and stability of the final pre-welding shape, namely, of the ridges 118a, 118b.

After the desired pre-welding shape has been transferred into the first segment 110, the pre-shaped first segment 110 may be loaded into a set of welding electrodes 200 and the second wire segment 120 securely positioned in the reentrance 115 of the pre-welding shape for initiating the welding process, as it will be described in the following.

FIG. 3 shows schematically a side view (along the longitudinal direction BB′) of a set of welding electrodes 200 for performing shaping of the first segment 110 with the embedded second segment 120 and resistively welding the first segment 110 to the second segment 120 according to an embodiment. The set of welding electrodes 200 are part of the apparatus according to an embodiment with the pre-welding electrodes 100 described above.

The set of welding electrodes 200 is configured for applying an electrical potential difference between a first position P1 and a second position P2 along the longitudinal direction BB′ of the first segment 110 for welding the first segment 110 to the second segment 120 arranged in the reentrance 115 of the pre-welding shape, for e.g. after applying the pre-welding, shape-forming process described above.

The set of welding electrodes 200 comprises a first sub-set of welding electrodes 210, 211a, 211b to be arranged around a cross-section of the first segment 110 at the first position P1 for applying a first welding potential to the first segment 110. A second subset of welding electrodes 210′, 211a′, 211b′, in a number and shape identical to the electrodes forming the first subset, may be arranged around a cross-section of the first segment 110 at the second position P2, which is at a suitable distance from the first position P1, for applying a second welding potential, different from the first potential, and therefore establish an electrical potential difference along a given longitudinal length of the first segment 110. The distance between the positions P1 and P2 may be selected depending on the length desired for the welded joint and therefore, may vary depending on the specific application, such as type of materials to be welded and the cross-sections of the first and second wires.

In addition, the set of welding electrodes 200 may further comprise a set of insulating elements (for e.g. elements 220, 221′ in FIG. 3) to be arranged around a cross-section of the first segment 110 and at an intermediate position P3 between the first and second positions P1, P2 for electrically insulating the first subset of welding electrodes 210, 211a, 211b from the second subset 210′, 211a′, 211b′. The welding currents are therefore supplied to the first segment 110 by the first and second subsets of welding electrodes located at the first and second positions P1 and P2, respectively.

In addition, one or both of the first subset of welding electrodes 210, 211a, 211b and the second subset 210′, 211a′, 211b′ is configured to further change the shape of the first segment 110 cross-section placed in-between into a predetermined welding shape, after the second segment 120 has been accommodated in the reentrance 115 and prior (or in simultaneous) to the application of the welding potential difference. Such welding shape is selected such as to improve the contact resistance between the first segment 110, the second segment 120 and the respective welding electrodes 200 and therefore, to achieve a more homogeneous distribution of welding current densities, as it will be now described with reference to FIGS. 4A and 4B.

FIG. 4A shows schematically a cross-sectional view of the first subset of welding electrodes 210, 211a, 211b arranged around the cross-section of the first segment 110 at the first position P1 (i.e. more specifically, covering a region of the first segment 110 about the first position P1). The first subset of welding electrodes 210, 211a, 211b includes a base welding electrode 210 for loading the pre-shaped first segment 110 thereon and two compression welding electrodes 211a, 211b that are arranged at specific radial directions on a side of the first segment 110 opposed to the base welding electrode 210 for applying inward pressure on specific locations of the first segment cross-section.

As depicted in FIG. 4B, the compression welding electrodes 211a, 211b can be moved towards the base electrode 210, for e.g. along the radial directions indicated by the arrows in FIG. 4B, for exerting pressure onto the first segment 110 loaded thereon. Thus, after the second segment 120 has been accommodated in the reentrance 115 provided for this effect in the pre-welding shaped first segment 110, inward pressure can be applied on the pre-shaped cross-section of the first segment 110 by the compression welding electrodes 211a, 211b so as to bring the inner surface of the reentrance 115 into closer contact with the second segment 120 and compact the strands of the first segment 110 around the second segment 120 into a welding shape, which prepares the first segment 110 cross-section for the subsequent application of welding currents.

As illustrated in FIG. 4B, the compression welding electrodes 211a, 211b and the base welding electrode 210 may be positioned with an angular separation of 120° around the longitudinal direction BB' such that the base 117 of the pre-welding shaped first segment 110 is supported on the base welding electrode 210 and the compression welding electrodes 211a, 211b respectively apply a radial pressure on the parallel ridges 118a, 118b, thereby causing the respective ridges 118a, 118b to bend towards the second segment 120 placed in the reentrance 115. Moreover, the faces of the compression welding electrodes 211a, 211b and the base welding electrode 210 that come into contact with the first segment 110 are planar in an embodiment so that the resulting welding shape of the first segment cross-section 110 is approximately a triangular shape with regular surfaces forming a 60° angle in-between. In this configuration, the second segment 120 accommodated in the reentrance 115 becomes fully surrounded by the bent ridges 118a, 118b and as a result, the contact between the first and second segments 110 and 120 is significantly improved. In addition, the regular, planar surfaces of the triangular welding shape allow for an even distribution of welding current densities across the interface with the welding electrodes during the subsequent welding process, which results in a more homogeneous generation of heat and consequently, on welded joints with improved quality.

In order to achieve the same benefits provided by the first subset of welding electrodes 210, 211a, and 211b in terms of homogeneous distribution of welding current densities and improved welding quality over a given longitudinal length of the first segment 110, the second subset of welding electrodes 210′, 211a′, 211b′ to be arranged around the cross-section of the first segment 110 at the second position P2 shown in FIG. 3 may be provided in number and shape identical to the first subset of welding electrodes 210, 211a, and 211b. Namely, the second subset of welding electrodes 210′, 211a′, 211b′ may also include a base welding electrode 210′ for supporting the first segment 110 at a region about the second position P2 and compression welding electrodes 211a′, 211b′, similar to the compression welding electrodes 211a, 211b of the first subset, and which are arranged along radial directions parallel to the radial directions of the compression welding electrodes 211a, 211b such as to apply inward pressure on the parallel ridges 118a, 118b of the pre-welding shaped first segment 110 held by second subset.

After the cross-section of the first segment 110 has been modified into the desired welding shape and compacted around the second segment 120, welding currents may be applied via each of the welding electrodes 210, 211a, 211b of the first subset at region P1 and the welding electrodes 210′, 211a′, 211b′ of the second subset at the region P2, such as depicted by the direction of the arrows in FIGS. 5A and 5B. As it can be seen from FIG. 5A, the triangular cross-section of the first segment 110 and the flat contact faces of the welding electrodes 210, 211a, 211b allow for a better electrical contact during the application of the welding currents than in the conventional techniques, and consequently, makes possible to reach an homogeneous distribution of the heat generated by the welding currents at the contact surfaces. A similar effect is achieved with the second subset of welding electrodes 210′, 211a′, 211″ located at the region P2.

The set of insulating elements 220, 221a, 221b shown in FIG. 3 may also be provided in number and shape similar to the first and/or second sub-set of welding electrodes described above. For instance, the insulating elements 220, 221a, 221b may include a base element 220 for holding the first segment 110 at the intermediate region P3 between the first and second regions of the first segment 110 held by the first and second subsets of welding electrodes, and include compression elements 221a, 221b to be arranged along radial directions in parallel to the radial directions of the compression electrodes of the first and/or second subsets of welding electrodes for applying inward pressure on the first segment 110 at the intermediate region along parallel radial directions. Consequently, the cross-section of first segment 110 with the embedded second segment 120 can be also modified to the predetermined welding shape at the intermediate position P3, so that the first segment 110 with the embedded second segment 120 has a regular cross-section that remains substantially constant along the entire longitudinal length of the first segment 110 between the first and second positions P1 and P2. In addition, a stable and durable welded joint can be obtained along the entire length between the first and second positions P1 and P2 of the first segment 110 because the heat generated by the welding current supplied across the first segment 110 is sufficient to achieve welding between the first and second segments 110, 120 at the intermediate region. As a result, a compact welded joint of the first and second segments of an improved quality may be obtain along the entire length between regions P1 and P2.

The design of the set of welding electrodes 200 described above thus eliminates the shortcoming presented by the conventional welding technique shown in FIG. 7, where the difference in the contact surfaces between the first wire 10 and the second wire 20 leads to welding currents of different densities being generated at the wires interface with a negative impact on the quality of the final joint.

The intensity of the welding current to be applied is selected such as to cause melting of the multi-stranded wires of the first segment 110 loaded between the welding electrodes 200. In addition, in order to promote welding to the second segment 120, the first and/or second subsets of welding electrodes may apply a controlled pressure onto the first segment 110, similar or different to the inward pressure used for modifying the shape of the first segment 110 cross-section into the welding shape, while the welding current is being supplied. However, since it is not desirable to have a very low cross-section resistance for obtaining a welded joint with good quality because the amount of heat generated by the supplied welding current depends on the resistance across the first segment 110. Since this resistance may decrease considerably under the application of pressure due to the distance between the wires of the multi-stranded cable being reduced, the pressure applied by the first and/or second subsets of welding electrodes onto the first segment 110 may be adjusted such as to achieve a given amount of resistance across the strands of the multi-stranded cable 10 that is sufficient for generating sufficient heat for welding while promoting the contact between the first and second segments 110, 120 to be welded. The most suitable magnitude of the welding pressure depends on several parameters and the particular application, such as the area of contact, diameter of the wires, wire material, and the like. For instance, a pressure in the order of 100 N/mm²may be sufficient for forming a welded interconnection of a sensor wire, such as a Dumet wire, to multi-stranded cables currently used in standard applications.

The configuration of the welding electrodes 200 described above results in a welded joint of the first segment with the embedded second segment 120 that exhibits a triangular cross-section at the end of the welding process, as shown in FIGS. 6A and 6B. However, it may be envisaged to use other shapes for the welding electrodes 200 and/or pre-welding, shape-forming electrodes 100 that allow forming a reentrance on the pre-shaped first segment 110 for accurately positioning the second segment 120 and which promotes a full encirclement of the second segment 120 by the first segment 110 prior to the application of the welding currents so as to achieve an homogeneous distribution of welding current densities. For instance, pre-welding, shape-forming electrodes may be provided with a shape-forming structure adapted to provide a pre-welding shape with a semi-hexagonal shape which is then finalized into a hexagonal welding shape by a set of welding electrodes 200 having a suitable number of compression electrodes at respective angular positions for completing the hexagonal shape of the first segment cross section via compression. Therefore, the number and angular positioning of the compression electrodes forming the set of welding electrodes is not limited to the illustrated embodiments and may be selected depending on the specific welding application, such as the desired welding shape, and consequently, differ from the configurations described above.

The set of pre-welding, shaping-forming electrodes 100 and/or the set of welding electrodes 200 according to the principles of the present invention may be used to implement a method of compact embedded wire welding in a line production of welded joints and interconnections, as described hereinafter for the case of a compact, embedded welded joint of a multi-stranded cable 10 to a single core wire, such as Dumet wire 20.

Firstly, the multi-stranded cable 10 is driven to a first station (pre-welding compacting station) to perform the pre-welding shape-forming process during which a certain length of the multi-stranded cable 10 (first segment 110) is loaded into the set of pre-welding electrodes 100 for transferring the desired pre-welding shape into the cross-section of the first segment 110 by compaction.

Secondly, after performing the pre-welding shape-forming process, the pre-shaped first segment 110 of the multi-stranded cable 10 may be automatically moved to the next station, i.e. a welding station, for optimizing the contact between the first segment 110 with the second segment 120 of a Dumet wire to be welded and perform the subsequent resistive welding. In this case, the pre-shaped first segment 110 is loaded into the base welding electrode(s) of the set of welding electrodes 200 and the second segment 120 of the Dumet wire 20 positioned in the reentrance 115 of the first segment 110 that was formed during the pre-welding shape-forming process, as shown in FIG. 4A. Alternatively, the first segment 110 may be loaded onto the base welding electrode(s) with the second segment 120 already positioned in the reentrance 115. The welding process may then be initiated by first bringing the compression welding electrodes 211a, 211b of the first subset and/or the compression welding electrodes 211a′, 211b′ of the second subset into contact with the first segment 110, for closing the borders of the reentrance 115 around the second segment 120 and compact the strands of the first segment 110 into a given welding shape, such as the triangular cross-section depicted in FIG. 5A.

A suitable welding current may then be supplied by the same welding electrodes that produced the compaction of the first segment 110 into the welding shape. For example, welding currents may be supplied from each face of the triangular cross-section so as to achieve an homogeneous distribution of welding heat that will melt the wires of the first segment 110 and form a welded joint with the embedded second segment 120. A controlled pressure may be applied by the set of welding electrodes onto the first segment cross-section while the welding currents are supplied in order to maintain the encirclement of the second segment 120 by the ridges 118a, 118b while ensuring sufficient resistance across the first segment 110 wires for generating the required welding heat.

The full insertion of the thinner wire segment 120 into the larger diameter cable 110 prior to welding avoids several problems that arise when different materials have to be welded. Such problems are in general associated with differences between the respective melting temperatures, material characteristics, and behavior of each wire material during a resistive welding process. For instance, in order to produce a satisfactory weld between copper and another metallic material, such as a nickel sheet, it is necessary to heat the area to be welded to a temperature sufficiently high so as to produce fusion or an alloying of the copper and the metal of the other metallic material. Copper can alloy with many metals and alloys, for e.g. nickel alloys. Nickel alloys (such as Ni-Fe) usually present welding temperatures higher than 1300° C. at low applied stress, while the melting temperature of cooper is typically around 1100° C. Copper alloys can also be welded, although each alloy will weld differently from another. Nevertheless, as long as the material to be welded can create an intermetallic alloy, it can be surrounded with cooper and welded thereto. In the case of a Dumet-based thermistor, the Dumet wire has a core made of an alloy of nickel-ferrum with a high welding temperature. However, it is possible to obtain a good welded joint between the Dumet wire and a cooper multi-stranded cable using the method of the present invention because the strands of copper wires will be placed around the Dumet wire prior to the application of the welding current. Thus, a further advantage of the present invention lies in that it does not require additional materials, such as solder and/or crimping, in order to produce a welded junction between dissimilar materials.

It is also known that the bi-metal composition of Dumet wires, where the nickel-iron core is surrounded by a copper cladding, poses several problems in the choice of materials for the respective welding electrodes. For instance, it has been reported that electrodes made of molybdenum or tungsten generally help to heat the copper cladding of the Dumet wire. However, these electrodes materials present the negative effect of sticking to the electrically resistive nickel-iron core once the electrode tip penetrates the copper cladding. It has also been reported that electrode sticking may be minimized by applying a negative polarity to the electrode that contacts the Dumet wire. However, restrictions on the polarity of the welding electrodes reduces flexibility of the overall welding process, since the positioning of the Dumet wire with respect to the welding electrodes must then be taken into account. Electrode sticking may also occur in the overlapping configuration of FIG. 7 if the wire segment 20 of higher resistivity melts well before the other cable segment 10 reaches a temperature sufficient for forming the welded junction.

Electrode sticking is a severe problem because it may disrupt or weaken the welded junction when the welding electrodes are removed at the end of the welding process. The full insertion of the thinner wire segment 120 into the larger diameter cable bundle 110 prior to welding, according to the principles of the present invention, eliminates the problems of electrode sticking described above, because the welding electrodes do not enter into direct contact with the wire segment 120 having the smaller cross-section and/or higher electrical resistivity, such as the Dumet wire. Moreover, since the welding potential is directly applied onto the compacted Cu bundle 110 (i.e. the material of lower electrical resistivity) after full insertion of the wire segment 120, it is ensured that both segments 110 and 120 will reach the required welding temperature at approximately the same time.

The set of pre-welding shape-forming electrodes 100 and the set of welding electrodes 200 of the present invention may be used in resistance welding machines known in the art, such as in line production, which are designed to be used with one or more welding electrodes and/or having a welding head that controls the pressure to be applied to the welding electrode(s). A welding power supply conventionally used for controlling the electric current applied via the welding electrodes may be used in combination with the set pre-welding shape-forming electrodes 100 and/or the set of welding electrodes 200 of the present invention for controlling the currents and potentials applied by the electrodes during the compaction and welding process.

The principles of the present invention may also be advantageously applied for electrically connecting sensors to external circuitry, such as in the automobile industry. Typically, the wire leads coming from a sensor are of a very small gauge. For instance, wire leads with a diameter of less than 0.3 mm are common in sensor devices such as the Dumet thermistor. On the other hand, the equipment interface in the car (or other application) is usually using a much larger diameter (gauge) wire—greater than 0.8 mm. The resistance welding of such dissimilar sized components can be very problematic. The welded joint also poses concerns in terms of reliability and lifetime as their stability is particularly challenged by the vibrations in the vehicle. In addition, the materials of the sensor wire can be very different from the wire used for the interconnection in the car. For instance, interconnection interfaces of vehicles commonly have large wires made of a very high Cu content alloy, while the wires used in a sensor may be of a quite different material, such as a glass beaded thermistor with a Dumet wire, which is a copper cladded steel wire.

In conclusion, the principles of the present invention may be advantageously used (but not limited to) in many applications that require forming an electrical interconnection or joint between electrical cables or wires of dissimilar materials, structure and sizes, which is durable and highly reliable. In particular, the present invention may be advantageously used in applications where the relative difference in thickness between two wires of metal alloys to be joined is significantly high. A further technical advantage of the present invention lies in the fact that a highly reliable welded joint is achieved without the need of any additional material(s) during the welding process since the joint of an intermetallic compound may be created from materials which have strong differing melting temperatures and specific resistances. This represents a significant reduction in costs and time savings of the overall welding process. The present invention is also suitable for joining cables/wiring in circuit designs with limited space. Furthermore, due to the relative small volume required by the sets of electrodes of the claimed invention, there can be advantages at further assembly steps, for e.g. for application of insulation materials.

Although certain features of the above exemplary embodiments may have been described using terms such as “bottom”, these terms were used for the purpose of facilitating the description of the respective features and their relative orientation only and should not be construed as limiting the claimed invention or any of its components to a particular spatial orientation. For instance, the present invention is not limited to use of the pre-welding shape-forming electrodes 100 illustrated in FIGS. 1-2 and/or the set of welding electrodes 200 shown in FIG. 3 in the depicted orientations. As an example, the shape-forming electrode 130 and the base electrode 140 may be inverted. Moreover, although the above embodiments were described in the context of the pre-welding shaped wire being a multi-stranded cable, the principles of the present invention are also applicable to other types of wires/cables that are deformable by compression and consequently, suitable for undergoing a pre-welding shape-forming process for embedding a second wire of smaller diameter to be welded, prior to applying a welding current, according to the principles of the present invention.

Device and Method for Compact Embedded Wire Welding Using a Shape-Forming Electrode

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