Lead and magnet wire connection methods using the Tin FUsing (Sn Fusing) method

Abstract

The technology for connecting lead and magnet wires for electric motors and electro-mechanical devices has been established for many years. Some of these methods such as brazing or "strip and crimp" (where the magnet wire enamel is removed and the wire bundle is crimped together) have been around since the first electromagnetic devices. While the process has changed little over the years, advancements in materials have allowed them to keep up with environmental and safety concerns, but not productivity and quality requirements. Newer methods of connection include the use of different styles of insulation displacement connections (IDC). While these technologies have significantly improved productivity, their range is limited and the process offers very little feedback for quality monitoring. The latest advancements in lead connection utilizing Tin Fusing (Sn fusing) technology and address all concerns of today's manufacturer. They are fast and efficient producing a very high quality connection with minimal safety or environmental risks to the operator. Furthermore, they offer feedback to maintain very tight controls on the process to insure that the connection is strong, low resistance and consistent.