Braided cable having a solidified end portion

Abstract: A flexible current carrying cable is provided having a cable and an end portion of the cable being solidified wherein the end portion is compressed into a unitary member having reduced voids and enabling brazing of the end portion to a current carrying apparatus. A method of forming a current carrying cable has the steps of inserting an end of a cable into a spot welding machine, solidifying the end of the cable within the spot welding machine at 593°C-1093°C at 4,1-6,9 bar.

Description: Field of the Invention This invention pertains to braided cable and, in particular, braided cable having a terminated end and a method of terminating the end of a braided cable via solidification. Braided cables are used for many applications including carrying current within or between electrical equipment. The use of braided cable to carry current is generally used due to the flexibility of the cable which allows bending of the cable in multiple orientations due to the braided arrangement of the cable. Also, the use of annealed copper in the braided cable is common which also provides for flexibility. However, the use of the braided cable is disadvantageous due to the multiple exposed fibers at the ends of the braided cable. The unfinished ends of a braided cable cannot be readily attached to a current receiving or providing apparatus. Attempts to braze an unfinished braided cable end directly to an apparatus are likely to fail because the widely spaced fibers of the braided cable will wick all of the brazing material into the braided cable reducing the flexibility of the cable. Prior methods of finishing or terminating the ends of braided cables in order to allow the brazing of the ends of the cables to apparatus include attaching a ferrule over the end of the braided cable. As described in U.S. Patent No. US-A-994,818, the ferrule was generally a metal or copper sleeve which was placed over and compacted to the end. The use of a ferrule to terminate a braided cable is inefficient and difficult to accomplish. The additional ferrule part increases the cost of the terminated cable and requires special machinery to compact the ferrule to the end of the cable. The use of a ferrule also provides a cable with excess resistivity which reduces the desired current flow in the braided cable. Further, the ferrule after compaction has gaps between the ferrule and the cable which further reduce the voltage carried by the cable and are required to be filled in with solder paste or other material. U.S. Patent Nos.US-A-4,922,072 and US-A-3,333,083 describe the welding of insulated wires. However, such prior art welding methods fail to take into account modern welding equipment and the great advantages gained therefrom in providing an improved solidified braided cable which is quickly and easily formed having a lack of voiding areas, is water-proof, sustaining no physical degradation after sustaining great pull forces, vibration and torquing and providing inconsequential voltage drops. A new and improved terminated braided cable is provided by the present invention. The cable avoids the need to attach a ferrule or other crimping device and allows the terminated braided cable to be attached directly to apparatus with improved current conduction and cost savings. It is an object of the present invention to provide a braided cable which may be successfully attached to apparatus without the use of additional parts to terminate the cable. It is another object of the present invention to provide a braided cable which may be terminated quickly and inexpensively. It is a further object of the present invention to provide a braided cable which is terminated in a manner which provides a limited voltage drop. It is another object of the present invention to provide a braided cable which provides for minimal water absorption. It is a further object of the present invention to provide a terminated end portion having maximum mechanical strength. DE-A-419005 discloses a braided cable having an end formed into a loop and solidified. GB-A-286346 discloses an electrical connector comprising a plate having apertures at each end a kinked portion to serve as a flux barrier during soldering. The present invention provides a flexible current carrying braided cable, the cable having an end portion solidified via a spot welding machine; and being formed adjacent to said end portion with a U-shaped, oxidized bump extending in a direction beyond the plane of the ends (61,62) of the cable. The invention also provides a method of forming a braided cable having a solidified end, as claimed in Claim 8. These and other features of the invention are set forth below in the following detailed description of the presently preferred embodiments. Brief Description of the Drawings FIG. 1 is a perspective view of a braided cable having solidified ends; FIG. 2 is a side elevation view of a braided cable having solidified ends; FIG. 3 is a photocopy of an enlarged micrograph of a prior art termination of a braided cable; FIG. 4 is a photocopy of an enlarged micrograph of a terminated end portion of a braided cable; Fig 5 is a perspective view of an embodiment of a braided cable having solidified ends; and Fig 6 is an enlarged cutaway view of Fig 5 taken at line 6-6. Detailed Description of the Preferred Embodiments Turning to Fig 1, a braided cable 10 is shown having a first end 20 and a second end 30. Individual fibers 15 are braided to provide a flexible cable 10. In a preferred embodiment, annealed copper cable is used. A cable 10 of any shape, width or thickness may be terminated by the process of this invention. The first end 20 includes a hole 25 which is used for attaching the end 20 to an apparatus. The first end 20 may be connected to a current originating apparatus, and the second end 30 of the cable 10 may be connected to a current receiving apparatus. Upon attachment of the cable 10, current is carried from the first end 20 to the second end 30. Turning to FIG. 2, the cable 10 is shown having the first end 20 and the second end 30. The fibers 15 of the cable 10 are braided to form the cable 10. The ends 20,30 are solidified to provide a terminated end which is compacted into a solid end portion 20,30 which may be brazed directly to an apparatus. This may be accomplished without adding an additional piece such as a ferrule or needing to crimp the braided cable. The end portion 20,30 may also be attached to the apparatus by ultrasonically welding the end portion to the apparatus. In a preferred method of solidifying the end portions 20,30 of the cable 10, a Peer 150 KVA spot welder was modified by adding a Unitrol 9180-C thermo feedback control unit. The thermo feedback control unit allows the spot welder to ramp-up to a maximum power and rolls back the power at a specified temperature setting and maintains the desired temperature setting. An end of the cable was placed in the spot welder. The spot welder was set to between 593°C (1100°F) and 1093°C (2000°F) and 4·1.10 5 to 6·9.10 5 Pa (60 to 100 psi). These settings varied depending on the thickness and shape of the cable being terminated. The cable was held under the spot welder for between one-half second and two seconds to provide a solidified first end 20. For thicker cables, the cable must be rotated for solidifying a first side and then a second side. This process was repeated to provide a solidified second end 30. The spot welder was further modified to include custom weld tips. These tips are customized for the specific terminated shape of the cable desired. The tips have recessed areas so that placement of the end portions 20,30 therebetween terminate and solidify the ends in a single, quick method. The use of the spot welder with customized tips is a vast improvement over prior art methods because it provides for quick and highly finished solidified ends. This process provided for solidified cable ends which also have superior performance characteristics over the prior art ferrule crimped cables. The solidified cable ends of military specification MIL-T-13513B(AT) provide voltage drop measurements that do not exceed 5 millivolts when a current of 205 amps is passed and provide a reduced voltage drop of less than 2.5 mV; compared to the ferrule crimped cables which exceed 2.5 mV. The solidified cable ends do not exceed by more than 5°C (9°F) the temperature of the braid material when 205 amps is passed. The solidified cable end does not exceed by more than 10°C (18°F) the temperature of the attached braid when connected to a circuit so that 256 amps could pass through, return to room temperature and pass a current of 410 amps for a period of five minutes, and the solidified ends exhibit better voltage drop measurements than ferrule crimped cables. The solidified cable ends withstand a minimum mechanical strength pull of 485 pounds pull force without breaking or becoming distorted. The solidified end may sustain a minimum pull force of approximately 2158N (485 pounds) after being vibrated for one hour in each of three mutually perpendicular axes at an amplitude of 1·524mm (.060 inches) and a frequency of 10-55 to 10 Hertz, with a frequency range accomplished once each minute and brake at the braid as opposed to the ferrule crimped cable in which the ferrule pulls from the braid. The solidified end withstands a bolt being torqued onto it at a torque of 11·3 joules (100 inch pounds) without physical degradation. The solidified end provides for a water proof area showing no evidence of water absorption, whereas the ferrule crimp will absorb water. The solidified crimp exhibits very little voiding whereas the ferrule crimp has substantial voiding. FIG. 3 is a cross-sectional view enlarged fifty times of a prior art cable having a ferrule terminated thereon. The ferrule 40 is shown surrounding the cable 41. The cable comprises individual fibers 15. The ferrule 40 is compacted around the cable 41. The process of terminating the ferrule 40 onto the cable 41 leaves a gap 43 between the ferrule 40 and the cable 41. The gap 43 causes a voltage drop when current is transferred from the cable 41 to the ferrule 40. As well, the fibers 15 of the cable 41 are loosely oriented so that voids 45 occur between the fibers 15. The voids 45 and the gap 43 also allow for water absorption which causes water condensation. FIG. 4 is a cut-away view of a solidified cable of the present invention enlarged fifty times wherein the cable 50 includes fibers 52 which are closely compacted. The use of the solidification to terminate the end portion of the cable 50 reduces the gaps 43 and voids 45 which occurred in the prior art (FIG. 3). This solidified cable may be attached to a substrate via brazing, bolting, ultrasonic welding or soldering. Fig. 5 and 6 disclose an embodiment of the present invention. A braided cable 60 having solidified ends 61, 62 includes an oxidation bump 70. The cable 60 has a maximum voltage drop of 2.5 mV when a current of 205 amps is passed and measured after thermal stabilization. Each solidified end 61,62 may withstand a pull force of 485 pounds and may be waterproof. In a preferred embodiment, the method of forming the cable having an oxidation bump 70 includes the steps of: inserting an end portion 61,62 of a cable 60 into a spot welding machine (not shown); solidifying the end portion 61,62 of the cable 60 via the spot welding machine at 593°C-1093°C (1100°F-2000°F) at 6·9.10 4 -6·9.10 5 Pa (10-100 psi); forming the U-shaped bump 70; and oxidizing the bump 70; Each end portion 61,62 is compressed into a unitary member having reduced voids and enabling attachment of the end portions 61,62 to a current carrying apparatus. The U-shaped bump 70 is formed to extend the cable 60 in a direction beyond the plane of the ends 61,62 of the cable 60. The bump in then oxidized by the application of two prongs to the sides of said bump and heating said bump to a specified temperature. By way of example and not by limitation, the following tests are offered. TEST 1 - Initial Voltage Drop Requirements: Voltage drop measurements shall not exceed 5 millivolts, when measured in accordance with MIL-T-13513B(AT) (Military Specification, U.S. Army Tank-Automotive Command), paragraph 4.6.3. Procedure : The samples were connected into a circuit adjusted to pass a current of 205 amps. The millivolt drop was measured from the edge of the termination to a point on the braided cable 6·35 mm (1/4 inch) inward. The voltage drop and test current values were recorded. This was done in the as received condition (cold) and after the assembly had thermally stabilized. Initial Voltage Drop Sample Number Direct Current (amperes) Voltage Max. Limit (mv) Actual Pass/Fail 1 205 5 2.02 Pass 2 205 5 1.50 Pass 3 205 5 0.71 Pass 4 20.5 5 2.61 Pass 5 205 5 3.71 Pass 6 205 5 3.51 Pass * Samples 1-3 are cables having solidified ends. Samples 4-6 are cables having ferrule crimps. Results : When the samples were tested at a test current of 205 amps and measured after thermal stabilization, they were all observed to meet the requirements of MIL-T-13513B(AT), i.e. a voltage drop of less than 5 millivolts. It was observed that the solidified end samples exhibited a lower voltage drop result than the cable having ferrule crimps. TEST 2 - Current Rating Requirements : The temperature of the termination (solidified end or ferrule crimp) shall not exceed by more than 5°C (9°F) the temperature of the braid material, when tested as specified in MIL-T-13513B(AT), paragraph 4.6.4. Procedure : The assemblies were connected into a test circuit adjusted to pass 205 amps of current. The current was maintained until the temperature of the terminated ends and the splice stabilized. These stabilized temperature values were recorded. The temperature was recorded by means of a thermocouple embedded in the terminated end and also in the braided material. All results are recorded in Table 2. Current Rating Sample No. Direct Current (amperes) Temp. °C (°F) Barrel Stranding Pass/Fail Barrel Stranding AT °C (°F) Max. Act 1 205 37.3 (99.2) 33.2 (91.8) 5 (9) 4.1 (7.4) Pass 2 205 40.3 (104.6) 35.9 (96.6) 5 (9) 4.4 (8.0) Pass 3 205 37.8 (100.0) 37.8 (100.0) 5 (9) 0 (0) Pass 4 205 38.4 (101.2) 33.0 (91.4) 5 (9) 4.9 (8.8) Pass 5 205 36.8 (98.3) 33.2 (91.7) 5 (9) 3.7 (6.6) Pass 6 205 33.4 (92.1) 31.7 (89.0) 5 (9) 1.7 (3.1) Pass * Samples 1-3 are cables having solidified ends. Samples 4-6 are cables having ferrule crimps. Results : All of the assemblies met the requirements of MIL-T-13513B(AT), there were no significant differences between the solidified ends vs. ferrule crimps, as far as the results of this test were concerned. TEST 3 - Current Overload and Post-Overload Voltage Drop Requirements : The terminated end (solidified end or ferrule crimp) temperature shall not exceed by more than 18°F the temperature of the attached braid, when tested as specified in MIL-T-13513B(AT), paragraph 4.6.5. The subsequent post-test voltage drop measurements shall meet the requirements specified in Table I of MIL-T-13513B(AT), and shall be less than 8 millivolts. Procedure : The samples were connected into a circuit so that 256 amps could pass through them. The stabilized temperatures of the terminated ends (solidified end and ferrule crimp) and the braid material were recorded. Then, the samples were allowed to return to room temperature. Then, a test current of 410 amps was allowed to pass through the samples for a period of five minutes. The stabilized temperatures of the terminated ends (solidified or ferrule crimp) and of the braid material were recorded. The samples were then allowed to return to room temperature and were tested for voltage drop as indicated in the first section of this report. All results are recorded in Table 3. Current Overload - 125% Sample No. Direct Current (amperes) Temp. °C (°F) Barrel Stranding Pass/Fail Barrel Stranding AT °C (°F) Max. Act 1 256 43 (110) 38 (100) 10 (18) 5 (10) Pass 2 256 50 (122) 42 (108) 10 (18) 8 (14) Pass 3 256 45 (113) 47 (116) 10 (18) -2 (-3) Pass 4 256 50 (122) 40 (104) 10 (18) 10 (18) Pass 5 256 49 (120) 39 (103) 10 (18) 10 (17) Pass 6 256 39 (102) 39 (102) 10 (18) 0 0 Pass * Samples 1-3 are cables having solidified ends. Samples 4-6 are cables having ferrule crimps. Current Overload - 200% Sample No. Direct Current (amperes) Temp. °C (°F) Barrel Stranding Pass/Fail Barrel Stranding AT °C (°F) Max. Act 1 410 48 (118) 44 (111) 10 (18) 4 (7) Pass 2 410 53 (128) 45 (113) 10 (18) 8 (15) Pass 3 410 48 (118) 43 (109) 10 (18) 5 (9) Pass 4 410 51 (124) 43 (110) 10 (18) 8 (13) Pass 5 410 48 (118) 40 (104) 10 (18) 8 (14) Pass 6 410 39 (103) 41 (106) 10 (18) -2 (-3) Pass * Samples 1-3 are cables having solidified ends. Samples 4-6 are cables having ferrule crimps. Post-Overload Voltage Drop Sample Number Direct Current (amperes) Voltage Max. Limit (mv) Actual Pass/Fail 1 205 8 1.3 Pass 2 205 8 1.6 Pass 3 205 8 0.7 Pass 4 205 8 3.1 Pass 5 205 8 4.1 Pass 6 205 8 3.8 Pass * Samples 1-3 are cables having solidified ends. Samples 4-6 are cables having ferrule crimps. TEST 3 - continued Results : All of the samples tested met the requirements of MIL-T-13513B(AT). There were no significant differences in the results obtained for the two types of samples when tested for current overload. However, when the post test voltage drop measurements were made, the samples with solidified ends exhibited lower (better) voltage drop measurements than the samples with the ferrule crimp. All results can be found in the data section of this report. TEST 4 - Mechanical Strength Requirements: The terminated ends (solidified ends or ferrule crimps) shall withstand a minimum mechanical strength of 2158N (485 pounds) pull force without breaking or becoming distorted to the extent of being unfit for further use. The samples shall be tested in accordance with MIL-T-13513B(AT), paragraph 4.6.6. Procedure : The test specimens were placed in a standard tensile testing machine and a sufficient force was applied to pull the cable to its minimum force rating of 485 pounds. The condition of the assembly was examined following the application of this minimum force requirement. Testing was performed at room temperature, and the speed of the test machine was 4 inches per minute. Two of the three samples of each type were tested by placing both ends of the sample in the grips of the universal test machine. One of three samples from each group was tested by placing a bolt through the pre-drilled hole in the terminated end and pulling on the bolt, while the other side was placed in the grips of a universal test machine. All results are recorded in Table 4. Test to Minimum Force Rating of 2158N (485 lbs) Sample No. Type Degradation at Minimum Force Rating Failure at Force Rating 1 Solidified. None 554 2 Solidified None 582 3 Solidified None 584 4 Ferrule None 647 5 Ferrule None 537 6 Ferrule None 518 TEST 4 - continued Results : All of the samples tested were pulled to a minimum force of approximately 2158N (485 pounds). There appeared to be no degradation to any of the samples tested, when pulled to this minimum force requirement. TEST 5 - Sinusoidal Vibration Requirements: The sample shall show no evidence of mechanical or electrical failure, when tested in accordance with MIL-T-13513B (AT), paragraph 4.6.7.1, vibration. Following the vibration test, the samples shall meet the mechanical strength test requirements. Procedure : One end of each sample was mounted on a vibration table with the other end of the sample secured to a stable support. The sample was vibrated for one hour in each of three mutually perpendicular axes at an amplitude of .060 inches and a frequency of 10 to 55 to 10 Hz, with the frequency range accomplished once each minute. Following vibration testing, the samples were - subjected to the mechanical strength test requirements defined earlier in this report, except that the samples were pulled to failure. Test to Failure After Sine Vibration Sample No. Type Degradation at Minimum Force Rating Failure at Force Rating 1 Solidified None 4648N (1,045 lbf) 2 Solidified None 3025N (680 lbf) 3 Solidified None 4746N (1,067 lbf) 4 Ferrule None 5542N (1,246 lbf) 5 Ferrule None 2913N (655 lbf) 6 Ferrule None 5040N (1,133 lbf) Results : All of the samples were subjected to, and successfully completed, the vibration test. There appeared to be no evidence of any physical degradation to any of the samples as a result of the vibration test. Following the vibration test, the samples were subjected to the mechanical strength test described in the previous section of this report. The samples were pulled to failure with a crosshead speed of one inch per minute. All of the samples broke at approximately the same force rating. The only difference was that some of the ferrule crimp samples did pull from the braid, whereas the solidified end samples tended to break at the braid. TEST 6 - Torque Test Requirements : The samples shall be checked for their ability to withstand a bolt being torqued onto them. A pre-drilled hole in the sample shall be placed over a tapped hole in an aluminum block, and a bolt shall be threaded through the sample into the block. The bolt shall be torqued to a torque of 11·3 joules (100 inch pounds). The sample shall be tested with and without washers. After each torque test, the samples shall be visually inspected for any evidence of degradation. Procedure : The samples were tested as outlined in the requirements section above, and all observations are recorded in Table 6. Torque Test Results Sample No. Type Significant Damage With Washer Without Washer 1 Solidified None None 2 Solidified None None 3 Solidified None None 4 Ferrule None None 5 Ferrule None None 6 Ferrule None None Results : There was no evidence of any physical degradation to any of the samples tested, as a result of the torque test. TEST 7 - Waterproofness Requirements : The samples, when tested as specified in MIL-T-13513B (AT), paragraph 4.6.7.2 shall show no evidence of leakage. Procedure : Three inches of the termination end of the assembly was immersed in water, in such a manner that hydrostatic pressure could be applied. Hydrostatic pressure of six pounds per square inch was applied to the water for six hours. The cable was then cut apart for evidence of leakage through the terminated end (solidified end or ferrule crimp). Results: The ferrule crimp sample was observed to absorb water. The solidified end sample showed no evidence of water absorption. TEST 8 - Microsections Requirements: One solidified end assembly and one ferrule crimp assembly shall be microsectioned using standard metallographic techniques. Samples shall be placed in an acrylic mounting compound, ground, and polished. The samples shall then be visually inspected for any evidence of voiding at the termination area (solidified end or ferrule crimp). Photographs of the microsections shall be taken. Results: The solidified crimp exhibited very little voiding in the termination area, whereas the ferrule crimp assembly did have voiding in this area. Micrographs are submitted with this application.

Claims: A flexible current carrying braided cable, the cable having an end portion (61) solidified via a spot welding machine; and being formed adjacent to said end portion with a U-shaped, oxidized bump (70) extending in a direction beyond the plane of the ends (61,62) of the cable. The braided cable of Claim 1 wherein said cable has a maximum voltage drop of 2.5 mV when a current of 205 A (amps) is passed and measured after thermal stabilization. The braided cable of Claim 1 wherein said solidified end will withstand a pull force of 2158N (485 pounds). The braided cable of Claim 1 wherein said cable has each end (61,62) solidified. The braided cable of Claim 1 wherein said oxidised bump (70) is a U-shaped indentation of said cable. The braided cable of Claim 1 wherein said end portion (61) is compressed into a unitary member having reducing voids and enabling attachment of said end portion to a current carrying apparatus. The braided cable of Claim 1 wherein said end portion (61) is waterproof. A method of forming a braided cable having a solidified end (61) comprising the steps of: inserting an end portion (61) of a cable into a spot welding machine; solidifying the end portion (61) of the cable via the spot welding machine at 593°C-1093°C (1100°F-2000°F) at 6.9.10 4 -6.9.10 5 Pa (10-100 psi); forming a U-shaped bump (70) to the cable; and oxidizing said bump. The method of Claim 8 wherein said spot welding machine is calibrated via a thermo feedback control unit. The method of Claim 8 wherein said end portion (61) is solidified via a customized tip of the spot welding machine. The method of Claim 8 wherein oxidation of said bump is caused by the application of two prongs to the sides of said bump and heating said bump to a specified temperature.

Inventors: LINDSEY DENIS, NGUYEN SON, OGDEN CHRISTOPHER, SIDER JOHN A, LINDSEY, DENIS, NGUYEN, SON, OGDEN, CHRISTOPHER, SIDER, JOHN A.
Applicants: METHODE ELECTRONICS INC, METHODE ELECTRONICS, INC.
Application year: 1995
Main classification: H01B5
IPC codes: H01R11, H01R43