Braided Terminal Connection Structure for Accurate Laser Welding
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Solution Overview
Problem
Existing methods for connecting shielded cables to terminals face challenges in productivity and accuracy due to the need for dedicated molds and tools, and the inefficiency of laser welding flexible shield braids, which require increased irradiation time and power to achieve reliable connections.
Innovation Solution
A braided part connection structure where a conductive member with a braid joining portion, featuring a comb-teeth shape with notched holes and cantilevered protruding pieces, is laser-welded onto a shield braid, improving positioning accuracy and reducing heat transmission, thus enhancing connection reliability and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the shield terminal and the shield braid are joined by a laser joining method, then the number of jigs can be reduced and takt time can be shortened, but joining accuracy deteriorates due to the unstable shape of the flexible shield braid
Solution Approach 1:
The shield braid end is preliminarily formed into a flat plate shape before laser welding. This preliminary shaping stabilizes the otherwise unstable flexible braid, enabling accurate laser welding without requiring additional jigs or fixtures during the welding process itself.
Solution Approach 2:
The physical state of the shield braid end is changed from a flexible, unstable braid structure to a stable flat plate configuration. This parameter change in shape and rigidity allows the laser welding process to achieve high precision without the interference of braid movement or deformation.
2Speed
If laser light is used to weld the overlapping portion of the shield braid and the conductive member, then joining speed can be increased, but heat energy escapes to the periphery requiring increased irradiation time and power
Solution Approach 1:
The conductive member is segmented with multiple through-holes that divide the welding area into separate zones. This segmentation confines the heat energy within each zone during laser welding, preventing heat escape to the periphery and reducing the total irradiation time and power required.
Solution Approach 2:
The conductive member incorporates a porous structure with multiple through-holes that act as heat barriers. These holes disrupt heat conduction paths, trapping heat energy at the welding interface and preventing it from escaping to surrounding areas, thereby improving welding efficiency.
3Reliability
If dedicated molds and tools are used for crimping each electric wire and shield terminal with different diameters, then connection reliability can be maintained, but productivity deteriorates
Solution Approach 1:
The laser welding process serves as a universal joining method that can accommodate shield terminals and braids of different diameters without requiring dedicated molds or tools for each size. The flat plate configuration of the braid end and the through-hole structure of the conductive member create a universally applicable welding interface.
Solution Approach 2:
The mechanical crimping system, which requires dedicated molds for different diameters, is replaced with a laser welding system. This substitution eliminates the need for multiple mechanical tools while maintaining connection reliability through precise laser welding of the flat plate braid end to the conductive member.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration allows for high-reliability connections with reduced takt time and cost, as the braid joining portion's design stabilizes laser focus and minimizes heat escape, enabling efficient laser welding without increasing irradiation time or power.
Implementation Method 1
wherein the welded portion is laser-welded onto the shield braid
Implementation Method 2
by locally irradiating laser light, both an electric wire and a conductive metal plate are melted and then solidified and joined together
Data Source
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AI summary
A braided part connection structure includes a conductive braid and a conductive member electrically connected and fixed to the braid and made of a conductive plate material. The conductive member includes a braid joining portion. The braid joining portion includes, at a part of the conductive member in a longitudinal direction of the conductive member, a plurality of openings formed at intervals with each other along a direction intersecting the longitudinal direction and a welded portion defined by two adjacent openings of the plurality of openings. The braid joining portion is provided on the braid in an overlapping manner and the welded portion is laser-welded onto the braid.