Patent ID: 7355142

Claim:
An electrode for use during resistance welding of a first associated stranded metal workpiece to a second associated metal substrate workpiece by pressing and applying an electric current to superposed regions of the first and second workpieces, the electrode comprising: a main body; and, a tip portion on the main body, the tip portion defining i) a first contact region for pressed engagement with the first stranded metal workpiece as the electric current is applied to the superposed regions of the first and second workpieces during a welding operation and ii) a locating region for locating the first stranded metal workpiece at the first contact region during said welding operation, the locating region including a pair of spaced apart shoulder members having curved surfaces and defining a distal end of the electrode and forming a second contact region configured to establish substantially a line contact with said second associated metal substrate workpiece at a conclusion of said welding operation; wherein said pair of shoulder members are spaced apart by a gap; and, said first contact region is defined by a first surface of said tip portion located in said gap and spaced from said distal end of the electrode by a first predetermined distance; wherein said main body is an elongate cylindrical main body defining a longitudinal axis; and, said pair of shoulder members define a set of opposed containment surfaces oriented substantially in parallel with said longitudinal axis; wherein said curved surfaces of said pair of shoulder members are curved about a first axis substantially perpendicular to said longitudinal axis of the main body; wherein said first surface of the tip portion is a first arcuate surface curved about a second axis substantially parallel with the first axis defined by the curved surfaces of said pair of shoulder members and perpendicular with the longitudinal axis of the main body; and wherein: said main body has a first width in a direction perpendicular to said longitudinal axis; and, each of said second contact regions of the pair of shoulder members has a second width in said direction perpendicular to said longitudinal axis of less than half of said first width of said main body.