Butt-Welded Wire Connection Body With Reduced Joint Diameter

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Solution Overview

Problem

The existing resistance welding method for connecting electric wires requires additional steps such as moving an auxiliary ring and removing insulation coatings, and results in an increased diameter of the connection portion due to wire overlapping.

Innovation Solution

The electric wire connection body is achieved through butt welding of the first and second electric wires, with a connection portion housed inside an insulation coating body that matches the wire diameter, eliminating the need for additional insulation and reducing the connection diameter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If resistance welding with overlapping wires is used to connect electric wires, then the connection is achieved, but the diameter of the connection portion increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidconnection portion diameter

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

Instead of overlapping wires and then insulating, the patent inverts the sequence by first providing insulation coating on the wires, then performing butt welding through the insulation material. This allows the connection portion to maintain the original wire diameter without enlargement from overlapping.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent replaces the traditional mechanical resistance welding method with laser beam welding. The laser beam can penetrate the insulation coating and directly weld the core wires together through butt joint, eliminating the need for overlapping wires and auxiliary rings, thus maintaining a compact connection diameter.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If resistance welding method is used to connect electric wires, then the connection is achieved, but additional work steps are required

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent applies preliminary action by pre-coating the wires with insulation material before the welding process. This eliminates the need for post-welding insulation steps and auxiliary ring installation, streamlining the manufacturing process while ensuring reliable electrical insulation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges multiple steps into one integrated process: the insulation coating serves both as electrical insulation and as a medium through which the laser beam can weld the core wires. This combines the insulation function and welding function into a single operational sequence, eliminating separate steps for auxiliary ring installation and post-welding insulation.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If auxiliary ring is used to seal weld portions in resistance welding, then electrical insulation is achieved, but the device complexity increases

Engineering Contradiction:

Improveelectrical insulationVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the auxiliary ring component by integrating the insulation function directly into the wire's own insulation coating. The insulation coating is designed to remain on the wire surface through the welding process, providing continuous electrical insulation without requiring separate auxiliary sealing components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The insulation coating serves multiple functions: it provides electrical insulation during normal operation, acts as a medium for laser beam transmission during welding, and maintains structural integrity throughout the connection process. This multi-functionality eliminates the need for separate auxiliary rings and post-welding insulation steps.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 method allows for easy and efficient welding of electric wires while reducing the diameter of the weld portion, improving stress resistance and space efficiency in applications such as temperature sensors.

Implementation Method 1

an irradiation step of irradiating the first electric wire and the second electric wire abutted on each other, with laser to form a connection portion by welding

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

The connection portion is formed by welding the core wire of the first electric wire and the core wire of the second electric wire

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 3

an insulation coating body covering a periphery of the connection portion

Methodology Applied

Scientific EffectElectrical insulation:

Data Source

PatentUS12308625B2Electric wire connection body, method of manufacturing electric wire connection body, sensor element, and method of manufacturing sensor element

Publication Date: 2025.05.20 SHIBAURA ELECTRONICS CO LTD

AI summary

An electric wire connection body includes a first electric wire, a second electric wire electrically connected to the first electric wire, a connection portion connecting the first electric wire and the second electric wire, and an insulation coating body covering a periphery of the connection portion. The connection portion is formed by butt welding of the first electric wire and the second electric wire.