US3916518A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method for making one-piece bimetallic connector
Assignee: Coatings Inc
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Filing: 1974-10-10
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Granted: 1975-11-04
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Expires: 1994-10-10
Abstract
Abstract An elbow-type loadbreak/deadbreak terminator or bushing for electrically connecting an insulated aluminum conductor wire to a copper terminal of an electrical device comprises an L-shaped insulated housing having intersecting passages, one of which accommodates a one-piece bimetallic (aluminum-copper) connector and the other of which accommodates a cylindrical copper probe threaded at its inner end. The connector comprises an aluminum portion and a copper portion welded together across their entire interface by an inertia welding process. An opening extends inwardly axially from the end of the aluminum portion of the connector for receiving the bare end of the aluminum wire which is crimped therein. A threaded opening extends inwardly transversely from a side of the copper portion of the connector for receiving the threaded inner end of the copper probe which screws thereinto. A method for making a one-piece bimetallic connector broadly comprises the steps of providing a cylindrical copper blank and a cylindrical aluminum blank, heat treating the aluminum blank, cleaning those faces of the blanks which are to be welded, welding the two blanks together by an inertia welding process and machining the joined blanks into a connector of desired shape.
Inventors
- 👤 Benjamin G Jones
- 👤 Richard B Leachy
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 04:37
CPC Classifications
H; H02; H02G; H02G15/00; H02G15/08; H02G15/10; H02G15/103; H01; H01R; H01R4/00; H01R4/58; H01R4/62; H01R43/00; H01R43/16; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49117; Y10T29/49204; Y10T29/49208; Y10T29/4921
Claims Analysis
Total Claims: 31
Claim 1
Independent Claim
143 words
A METHOD FOR MAKING A NOE-PIECE BIMETALLIC CONNECTOR HAVING A WIRE RECEIVING OPENING IN ONE END AND A THREADED TRANSVERSE PROBE RECEIVING OPENING NEAR ITS OTHER END FROM AN ALUMIMUM BLANK AND A COPPER BLANK FOR USE IN ONE OF A PAIR OF TRANSVERSELY INTERSECTING PASSAGES IN AN ELECTRICAL TERMINATOR FOR CONNECTION TO AN ALUMINUM WIRE IN SAID ONE PASSAGE AND TO A THREADED COPPER PROBE IN THE OTHER PASSAGE COMPRISING THE STEPS OF: ANNEALING SAID ALUMINUM BLANK TO A DESIRED DEGREE OF HARDNESS, CLEANING THOSE SURFACE OF THE ALUMINUM BLANK AND THE COPPER BLANK WHICH ARE TO BE JOINED TO REMOVED IMPURITIES, AND JOINING THE AMUMINUM BLANK AND THE COPPER BLANK ENTIRELY ACROSS SAID SURFACES IN AN UNINTERRUPTED INTERFACE BY THE PROCESS OF INERTIA WELDING WITHIN AN INTERVAL OF TIME NOT EXCEEDING APPROXIMATELY 5 MINUTES SUBSEQUENT TO SAID CLEANING OF SAID SURFACES.
Claim 2
Independent Claim
143 words
A METHOD FOR MAKING A NOE-PIECE BIMETALLIC CONNECTOR HAVING A WIRE RECEIVING OPENING IN ONE END AND A THREADED TRANSVERSE PROBE RECEIVING OPENING NEAR ITS OTHER END FROM AN ALUMIMUM BLANK AND A COPPER BLANK FOR USE IN ONE OF A PAIR OF TRANSVERSELY INTERSECTING PASSAGES IN AN ELECTRICAL TERMINATOR FOR CONNECTION TO AN ALUMINUM WIRE IN SAID ONE PASSAGE AND TO A THREADED COPPER PROBE IN THE OTHER PASSAGE COMPRISING THE STEPS OF: ANNEALING SAID ALUMINUM BLANK TO A DESIRED DEGREE OF HARDNESS, CLEANING THOSE SURFACE OF THE ALUMINUM BLANK AND THE COPPER BLANK WHICH ARE TO BE JOINED TO REMOVED IMPURITIES, AND JOINING THE AMUMINUM BLANK AND THE COPPER BLANK ENTIRELY ACROSS SAID SURFACES IN AN UNINTERRUPTED INTERFACE BY THE PROCESS OF INERTIA WELDING WITHIN AN INTERVAL OF TIME NOT EXCEEDING APPROXIMATELY 5 MINUTES SUBSEQUENT TO SAID CLEANING OF SAID SURFACES.
Claim 3
Independent Claim
157 words
A method for making a one-piece bimetallic connector having a wire receiving opening in one end and a threaded transverse probe receiving opening near its other end from an aluminum blank and a copper blank for use in one of a pair of transversely intersecting passages in an electrical terminator for connection to an aluminum wire in said one passage and to a threaded copper probe in the other passage comprising the steps of: annealing said aluminum blank to a desired degree of hardness; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; inserting the aluminum and copper blanks in an inertia welding machine; and operating said machine to join the aluminum blank and the copper blank along said surfaces in an uninterrupted interface by the process of inertia welding within an interval of time not exceeding approximately 5 minutes subsequent to said cleaning of said surfaces.
Claim 4
Independent Claim
157 words
A method for making a one-piece bimetallic connector having a wire receiving opening in one end and a threaded transverse probe receiving opening near its other end from an aluminum blank and a copper blank for use in one of a pair of transversely intersecting passages in an electrical terminator for connection to an aluminum wire in said one passage and to a threaded copper probe in the other passage comprising the steps of: annealing said aluminum blank to a desired degree of hardness; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; inserting the aluminum and copper blanks in an inertia welding machine; and operating said machine to join the aluminum blank and the copper blank along said surfaces in an uninterrupted interface by the process of inertia welding within an interval of time not exceeding approximately 5 minutes subsequent to said cleaning of said surfaces.
Claim 5
Independent Claim
139 words
A method for making a one-piece bimetallic connector having a wire receiving opening in one end and a threaded transverse probe receiving opening near its other end from an aluminum blank and a copper blank for use in one of a pair of transversely intersecting passages in an electrical terminator for connection to an aluminum wire in said one passage and to a threaded copper probe in the other passage comprising the steps of: annealing said aluminum blank to a desired degree of hardness; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined; and joining the aluminum blank and the copper blank across said surfaces in an uninterrupted interface by the process of inertia welding within an interval of time not exceeding approximately 5 minutes subsequent to said cleaning of said surfaces.
Claim 6
Independent Claim
139 words
A method for making a one-piece bimetallic connector having a wire receiving opening in one end and a threaded transverse probe receiving opening near its other end from an aluminum blank and a copper blank for use in one of a pair of transversely intersecting passages in an electrical terminator for connection to an aluminum wire in said one passage and to a threaded copper probe in the other passage comprising the steps of: annealing said aluminum blank to a desired degree of hardness; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined; and joining the aluminum blank and the copper blank across said surfaces in an uninterrupted interface by the process of inertia welding within an interval of time not exceeding approximately 5 minutes subsequent to said cleaning of said surfaces.
Claim 7
Independent Claim
189 words
A method for making a one-piece cylindrical bimetallic connector having a wire receiving opening in one end and a threaded transverse probe receiving opening near its other end from a cylindrical aluminum blank and a cylindrical copper blank for use in one of a pair of transversely intersecting passages in an electrical terminator for connection to an aluminum wire and to a threaded copper probe in the other passage comprising the steps of: providing an aluminum blank of high purity aluminum and a copper blank of high purity copper, annealing said aluminum blank to a hardness level of about 35 to 50 RH by heating at about 800*F for about three hours followed by a controlled 50*F per hour drop for about an additional 9 hours; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined by machining the aluminum surface and abrading the copper surface; joining the aluminum blank and the copper blank across the said surfaces in an uninterrupted interface by the process of inertia welding within approximately 5 minutes after cleaning said surfaces; and removing the flash from the weld.
Claim 8
Independent Claim
189 words
A method for making a one-piece cylindrical bimetallic connector having a wire receiving opening in one end and a threaded transverse probe receiving opening near its other end from a cylindrical aluminum blank and a cylindrical copper blank for use in one of a pair of transversely intersecting passages in an electrical terminator for connection to an aluminum wire and to a threaded copper probe in the other passage comprising the steps of: providing an aluminum blank of high purity aluminum and a copper blank of high purity copper, annealing said aluminum blank to a hardness level of about 35 to 50 RH by heating at about 800*F for about three hours followed by a controlled 50*F per hour drop for about an additional 9 hours; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined by machining the aluminum surface and abrading the copper surface; joining the aluminum blank and the copper blank across the said surfaces in an uninterrupted interface by the process of inertia welding within approximately 5 minutes after cleaning said surfaces; and removing the flash from the weld.
Claim 9
Dependent Claim
48 words
A method according to claim 4 including the steps of providing a wire receiving hole extending axially inwardly of the aluminum portion of the connector from an end thereof; providing a tapped probe receiving opening extending inwardly into said copper portion of the connector from a side thereof.
Claim 10
Dependent Claim
26 words
A method according to claim 5 including the steps of drilling said wire receiving opening; drilling said probe receiving opening; and tapping said probe receiving opening.
Claim 11
Dependent Claim
45 words
A method according to claim 5 including the steps of applying a rotational force of about 2,460 foot-pounds of energy, a surface rotational speed of about 250 feet per minute, and an axial load pressure of about 22,800 psi during said process of inertia welding.
Claim 12
Independent Claim
96 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of: providing an aluminum blank having a predetermined degree of hardness; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; and joining the aluminum blank and the copper blank across the entire interface of said surfaces in an uninterrupted interface within an interval of time not exceeding approximately 5 minutes subsequent to said cleaning of said surfaces by a welding process which produces a solid state bond.
Claim 13
Independent Claim
96 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of: providing an aluminum blank having a predetermined degree of hardness; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; and joining the aluminum blank and the copper blank across the entire interface of said surfaces in an uninterrupted interface within an interval of time not exceeding approximately 5 minutes subsequent to said cleaning of said surfaces by a welding process which produces a solid state bond.
Claim 14
Independent Claim
144 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of; heat treating an aluminum blank to a predetermined degree of hardness, said step of heat treating comprising the steps of bringing said aluminum blank to a hardness level of about 35 to 50 RH by heating the blank at a temperature of about 800* F for about three hours followed by a controlled 50* F per hour drop for about an additional 9 hours, cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; and joining the aluminum blank and the copper blank across the entire interface of said surfaces in an uninterrupted interface prior to the reformation of impurities on either of said surfaces by a welding process which produces a solid state bond.
Claim 15
Independent Claim
144 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of; heat treating an aluminum blank to a predetermined degree of hardness, said step of heat treating comprising the steps of bringing said aluminum blank to a hardness level of about 35 to 50 RH by heating the blank at a temperature of about 800* F for about three hours followed by a controlled 50* F per hour drop for about an additional 9 hours, cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; and joining the aluminum blank and the copper blank across the entire interface of said surfaces in an uninterrupted interface prior to the reformation of impurities on either of said surfaces by a welding process which produces a solid state bond.
Claim 16
Dependent Claim
35 words
A method according to claim 9 including the step of simultaneously squaring each of said surfaces to be joined during the step of cleaning to insure flush square contact therebetween during the step of joining.
Claim 17
Dependent Claim
36 words
A method according to claim 10 including the step of retarding the formation of impuritieS on said surfaces to be joined after cleaning and prior to joining by maintaining said blanks in a chemically inert atmosphere.
Claim 18
Independent Claim
165 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of: providing an aluminum blank of high purity aluminum and a copper blank of high purity copper; heat treating said aluminum blank to a hardness level of about 35 to 50 RH by heating at about 800* F for about three hours followed by a controlled 50* F per hour drop for about an additional 9 hours; cleaning those surfaces of the aluminum and the copper blank which are to be joined and joining the aluminum blank and the copper blank across said surfaces in an uninterrupted interface by the process of solid state welding prior to the reformation of impurities on said surface; said process of solid state welding including the steps of applying a rotational force, a surface rotational speed and an axial load pressure to said blanks which are related to the area of said surfaces during said process of solid state welding.
Claim 19
Independent Claim
165 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of: providing an aluminum blank of high purity aluminum and a copper blank of high purity copper; heat treating said aluminum blank to a hardness level of about 35 to 50 RH by heating at about 800* F for about three hours followed by a controlled 50* F per hour drop for about an additional 9 hours; cleaning those surfaces of the aluminum and the copper blank which are to be joined and joining the aluminum blank and the copper blank across said surfaces in an uninterrupted interface by the process of solid state welding prior to the reformation of impurities on said surface; said process of solid state welding including the steps of applying a rotational force, a surface rotational speed and an axial load pressure to said blanks which are related to the area of said surfaces during said process of solid state welding.
Claim 20
Dependent Claim
35 words
A method according to claim 12 wherein the step of cleaning said surfaces is carried out simultaneously with the step of squaring said surfaces to eliminate longitudinal eccentricity and possible erratic contact between said surfaces.
Claim 21
Dependent Claim
25 words
A method according to claim 13 wherein said steps of cleaning includes the step of abrading said aluminum blank and machining of said copper blank.
Claim 22
Dependent Claim
22 words
A method according to claim 14 wherein said step of joining is carried out within 5 minutes after said step of cleaning.
Claim 23
Dependent Claim
36 words
A method according to claim 14 including the step of retarding the formation of impurities on said surfaces to be joined after cleaning and prior to joining by maintaining said blanks in a chemically inert atmosphere.
Claim 24
Independent Claim
97 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of; heat treating an aluminum blank to a predetermined degree of hardness; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; and joining the aluminum blank and the copper blank across the entire interface of said surfaces in an uninterrupted interface within an interval of time not exceeding approximately 5 minutes subsequent to said cleaning of said surfaces by a welding process which produces a solid state bond.
Claim 25
Independent Claim
97 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of; heat treating an aluminum blank to a predetermined degree of hardness; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; and joining the aluminum blank and the copper blank across the entire interface of said surfaces in an uninterrupted interface within an interval of time not exceeding approximately 5 minutes subsequent to said cleaning of said surfaces by a welding process which produces a solid state bond.
Claim 26
Independent Claim
102 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of: providing an aluminum blank having a predetermined degree of hardness, said aluminum blank having a hardness level of about 35 to 50 RH; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; and joining the aluminum blank and the copper blank across entire interface of said surfaces in an uninterrupted interface prior to the reformation of impurities on either of said surfaces by a welding process which produces a solid state bond.
Claim 27
Independent Claim
102 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of: providing an aluminum blank having a predetermined degree of hardness, said aluminum blank having a hardness level of about 35 to 50 RH; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; and joining the aluminum blank and the copper blank across entire interface of said surfaces in an uninterrupted interface prior to the reformation of impurities on either of said surfaces by a welding process which produces a solid state bond.
Claim 28
Independent Claim
113 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of: providing an aluminum blank having a predetermined degree of hardness; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; squaring each of said surfaces to be joined during the step of cleaning to insure flush square contact therebetween during the step of joining; and joining the aluminum blank and the copper blank across entire interface of said surfaces in an uninterrupted interface prior to the reformation of impurities on either of said surfaces by a welding process which produces a solid state bond.
Claim 29
Independent Claim
113 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of: providing an aluminum blank having a predetermined degree of hardness; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; squaring each of said surfaces to be joined during the step of cleaning to insure flush square contact therebetween during the step of joining; and joining the aluminum blank and the copper blank across entire interface of said surfaces in an uninterrupted interface prior to the reformation of impurities on either of said surfaces by a welding process which produces a solid state bond.
Claim 30
Independent Claim
115 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of: providing an aluminuM blank having a predetermined degree of hardness; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; retarding the formation of impurities on said surfaces to be joined after cleaning and prior to joining by maintaining said blanks in a chemically inert atmosphere; and joining the aluminum blank and the copper blank across entire interface of said surfaces in an uninterrupted interface prior to the reformation of impurities on either of said surfaces by a welding process which produces a solid state bond.
Claim 31
Independent Claim
115 words
A method for making a one-piece bimetallic member from an aluminum blank and a copper blank comprising the steps of: providing an aluminuM blank having a predetermined degree of hardness; cleaning those surfaces of the aluminum blank and the copper blank which are to be joined to remove impurities; retarding the formation of impurities on said surfaces to be joined after cleaning and prior to joining by maintaining said blanks in a chemically inert atmosphere; and joining the aluminum blank and the copper blank across entire interface of said surfaces in an uninterrupted interface prior to the reformation of impurities on either of said surfaces by a welding process which produces a solid state bond.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-11-03 | 1979-05-05 | 1979-11-04 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-11-03 | 1983-05-05 | 1983-11-04 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-11-03 | 1987-05-05 | 1987-11-04 | $7700.00 | Window Closed / Lapsed |