Cable Connection Structure for Ultrasonic Welding Adaptability
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Solution Overview
Problem
Conventional cable connection structures face difficulties in performing ultrasonic welding when the flat cable is longer than the distance between the horn and the device main body, as the flat cable can hardly be bent orthogonal to its surface, limiting the use of connecting devices like ultrasonic welding devices.
Innovation Solution
A cable connection structure where the round and flat cables are pulled out in the same direction from a holder, allowing for connection using a connecting device like an ultrasonic welding device, regardless of the flat cable's length, with a waterproof exterior covering the connection to ensure reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the flat cable is set in the space between the horn and the device main body for ultrasonic welding, then the connection can be performed, but the flat cable cannot be used when its length exceeds the available space
Solution Approach 1:
The patent changes the spatial arrangement from the conventional method (cables extending in opposite directions from the holder) to a new configuration where both round cables and flat cable are pulled out in the same direction. This dimensional change in cable arrangement allows the flat cable to be positioned within the ultrasonic welding device's working space regardless of its length, resolving the contradiction between ease of operation and adaptability to cable length variations.
2Ease of manufacture
If the flat cable is pulled out in the opposite direction from the round cables, then the conventional connection method can be used, but the flat cable's inability to bend orthogonally limits its usability
Solution Approach 1:
The patent inverts the conventional cable arrangement by pulling out both round cables and flat cable in the same direction rather than in opposite directions. This inversion accommodates the flat cable's geometric constraints (inability to bend orthogonally) while maintaining ease of connection through ultrasonic welding, as the flat cable can now be properly positioned within the device's working space.
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
Enables reliable and efficient ultrasonic welding connections between round and flat cables of varying lengths, ensuring waterproofing and compatibility with different connecting devices.
Implementation Method 1
The core wires (not illustrated) of the round cables W1 and the conductors (not illustrated) of the flat cable W2 are connected by, for example, ultrasonic welding using an ultrasonic welding device 30
Data Source
AI summary
A cable connection structure includes a round cable, a flat cable, a holder holding an end portion of the round cable and an end portion of the flat cable and pulling out the round cable and the flat cable to overlap each other in a same direction, a connecting portion in which a core wire exposed from the end portion of the round cable and a conductor exposed from the end portion of the flat cable held by the holder are connected to each other, and a mold resin portion collectively covering the outer circumference of the holder and the outer circumference of the round cable and the flat cable pulled out from the holder.