Electricity: conductors and insulators – Conduits – cables or conductors – Combined
Reexamination Certificate
1999-10-26
2001-08-21
Reichard, Dean A. (Department: 2831)
Electricity: conductors and insulators
Conduits, cables or conductors
Combined
C174S09900B
Reexamination Certificate
active
06278064
ABSTRACT:
FIELD OF THE INVENTION
This invention relates generally to joining conductive materials together in electrical distribution equipment such as busway and, more particularly, to an arrangement for electron beam welding similar electrically conductive material to form a highly conductive joint. In addition, the invention also relates to a method for electron beam welding together similar conductive material.
BACKGROUND OF THE INVENTION
The present method for joining similar conductive material components such as busbars, in electrical busway is by gas-metal arc welding (GMAW). This method of joining the components together causes excess weld metal to form on the busbars which requires additional process time and cost for the removal thereof. Additionally, the GMAW method requires the use of a filler wire which has a lower conductivity than the busbar material, thereby creating a joint that is lower in conductivity than the busbars that are being welded together. This lower conductivity causes the resistivity of the joint to be higher than the original material and, hence, increases the heat rise in the joint when current is drawn through.
Accordingly, there is a distinct need for an improved arrangement and method to join similar conductive material that will provide a joint that is substantially as conductive as the original material. Additionally, the improved arrangement will not produce excess weld metal on the material, thereby eliminating the need to remove this excess weld metal and, hence, decreasing the process time and cost required to weld the material together.
SUMMARY OF THE INVENTION
The present invention provides an improved method to join similar conductive components in electrical distribution equipment which provides decreased process cycle time and increased conductivity in the joint.
The present invention provides an electrical distribution device including a first current carrying member made of a first material and partially defined by a surface and a second current carrying member made of a second material and partially defined by a surface. A joint is substantially located between the first current carrying member and the second current carrying member such that the joint is formed by electron beam means traversed between the first and second current carrying members at a first predefined energy level and a first predefined speed to penetrate, heat, and mix the first and second materials of the respective first and second current carrying members. The joint is further formed by the electron beam means subsequently traversed between the first and second current carrying members at a second predefined energy level and a second predefined speed to heat and melt the first and second materials of the joint to a level at or below the surfaces of the of the respective first and second current carrying members preventing the buildup of excess weld material at the joint and providing a finish to the surface of the weld material, the joint being constructed substantially of a portion of the first material of the first current carrying member and a portion of the second material of the second current carrying member.
In accordance with a preferred embodiment of the present invention, an arrangement is provided for welding together current carrying members of an electrical distribution device. The current carrying members are constructed from similar conductive material. The arrangement includes an electron beam gun capable of generating an electron beam sufficient to penetrate and heat the material, thereby providing mixing of the material to form a joint which is constructed substantially of a portion of each of the current carrying members.
The present invention also provides a method for welding current carrying members of a metal alloy material. Each of the members has a surface. The method includes: traversing an electron beam between a first and second current carrying members at a first predefined energy level and a first predefined speed to penetrate, heat, and mix the first and second materials of the respective first and second current carrying members to form a joint; and subsequently traversing between the first and second current carrying members at a second predefined energy level and a second predefined speed to heat and melt the first and second materials of the joint to a level at or below the surfaces of the of the respective first and second current carrying members preventing the buildup of excess weld material at the joint and providing a finish to the surface of the weld material, the joint being constructed substantially of a portion of the first material of the first current carrying member and a portion of the second material of the second current carrying member.
Also according to this invention, current carrying components in an electrical distribution device are welded together using a process which includes the steps of disposing busbar components adjacent to one another, activating an electron beam welding gun to generate an electron beam and passing the electron beam past the busbar components to form a joint.
REFERENCES:
patent: 4251709 (1981-02-01), Schumacher
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patent: 4665294 (1987-05-01), Hira et al.
patent: 5109594 (1992-05-01), Sharp et al.
patent: 5223672 (1993-06-01), Pinneo et al.
patent: 5798495 (1998-08-01), Hinkley et al.
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Barta John
Fixemar James V.
Hinkley Douglas A.
Golden Larry I.
Irfan Kareem M.
Nguyen Chau N.
Reichard Dean A.
Square D Company
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