Electric Cable Joining with Fixed Terminal Conductor Alignment
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Solution Overview
Problem
Existing methods for connecting terminal conductors from covered electric cables are prone to dispersion during the joining process, leading to unstable product quality due to improper positional arrangement.
Innovation Solution
An electric cable connection method that involves assembling covered electric cables, fixing terminal conductors with a fixing member, and using a joining device to connect the conductors in a predetermined arrangement, ensuring stability and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal conductors are disposed between horn and anvil for ultrasonic joining, then joining can be performed, but terminal conductors may disperse and positional arrangement becomes unstable
Solution Approach 1:
The patent applies preliminary action by positioning and fixing the terminal conductors in a predetermined arrangement on a support surface before the ultrasonic joining process begins. The holder member is provided with a support surface that maintains the positional arrangement of terminal conductors, ensuring they remain in the correct positions throughout the joining operation and preventing dispersion.
2Manufacturing precision
If terminal conductors are fixed with a fixing member, then positional arrangement is stabilized, but additional process steps and device complexity are introduced
Solution Approach 1:
The patent introduces a holder member as an intermediary component that provides a support surface for positioning terminal conductors. This holder member acts as a mediator between the terminal conductors and the ultrasonic joining device, maintaining their positional arrangement without requiring complex fixing mechanisms. The holder member is simply provided with a support surface that naturally maintains the predetermined arrangement.
3Reliability
If terminal conductors are assembled in predetermined arrangement before joining, then joining quality is improved, but assembly process time increases
Solution Approach 1:
The patent merges the positioning function into the holder member structure itself, which is already present in the ultrasonic joining device. The support surface of the holder member serves dual purposes: it holds the terminal conductors in predetermined arrangement and facilitates the ultrasonic joining process. This integration eliminates the need for separate positioning and joining operations, reducing total process time while maintaining joining quality.
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
The method ensures stable conductivity and improved work efficiency by preventing conductor dispersion and ensuring precise positional arrangement during the joining process.
Implementation Method 1
terminal conductors exposed from ends of covered electric cables are disposed between a horn and an anvil included in an ultrasonic joining device, and are joined together by the ultrasonic joining device
Data Source
AI summary
(Problem) To provide an electric cable connection method for joining terminal conductors in an assembled state and a joined electric cable. (Solution to the Problem) An electric cable connection method is a method for connecting exposed terminal conductors 21a of a plurality of covered electric cables 20 so as to be conductive. The electric cable connection method includes an assembly step s2 of assembling the covered electric cables 20; a fixing step s3 of fixing the terminal conductors 21a of the assembly of the plurality of electric cables 20 with a resin cover 50; and a joining step s4 of setting the plurality of covered electric cables having the plurality of terminal conductors 21a fixed with the resin cover 50 in an electric cable connection device 40, and joining the plurality of exposed terminal conductors 21a.