Reliable Wiring Material with Resistance Welding Innovation
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Summary
Problems
The existing methods for connecting insulation-coated single line conductors in wiring materials for vehicle applications face challenges such as poor connection reliability, thermal fatigue, and high material costs, particularly due to manual soldering or brazing processes, which are difficult to automate and prone to inconsistencies.
Innovation solutions
A wiring material with a tube-shaped connecting terminal that accommodates two single line conductors, where resistance welding is performed by energizing from the outer periphery, ensuring uniform bonding and high connection reliability, and a crush process is applied to enhance contact area and prevent thermal issues.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If soldering or brazing is conducted after pressure connection to improve connection reliability, then connection reliability is improved, but the process becomes difficult to automate and manufacturing complexity increases
Why choose this principle:
The patent extracts and eliminates the soldering or brazing step from the manufacturing process. By using resistance welding alone to achieve reliable electrical connection between the conductor and terminal, the patent removes the need for subsequent soldering or brazing operations, thereby simplifying the manufacturing process while maintaining connection reliability.
Principle concept:
If soldering or brazing is conducted after pressure connection to improve connection reliability, then connection reliability is improved, but the process becomes difficult to automate and manufacturing complexity increases
Why choose this principle:
The patent replaces the thermal joining processes (soldering or brazing) with a mechanical-electrical joining process (resistance welding). This substitution eliminates the need for flux, solder, or brazing filler metals, and allows for automated manufacturing while achieving comparable or superior connection reliability.
Application Domain
Data Source
AI summary:
A wiring material with a tube-shaped connecting terminal that accommodates two single line conductors, where resistance welding is performed by energizing from the outer periphery, ensuring uniform bonding and high connection reliability, and a crush process is applied to enhance contact area and prevent thermal issues.
Abstract
A wiring material is provided by electrically connecting a connecting terminal with two single line conductors arranged in parallel. The connecting terminal is provided with a tube-shaped section for storing two single line conductors, the two single line conductors are inserted into the tube-shaped section, resistance welding is performed by carrying electricity from the external of the tube-shaped section in a status where the tube-shaped section and the single line conductors are mutually brought into contact, and the connecting terminal is electrically connected with the two single line conductors.