Electric Cable Terminal Joining with Resin Fixing for Stable Conductivity
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Solution Overview
Problem
Existing methods for connecting terminal conductors of covered electric cables are prone to dispersion, leading to unstable product quality due to improper positional arrangement, which affects the conductivity and efficiency of the connection process.
Innovation Solution
The method involves fixing terminal conductors with a fixing member, such as a resin or metal member, adhesive, or pharmaceutical drug, to maintain a desired positional arrangement, followed by ultrasonic or laser joining, ensuring stable conductivity and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal conductors are disposed between horn and anvil for ultrasonic joining, then conductivity connection is established, but terminal conductors may disperse and positional arrangement becomes unstable
Solution Approach 1:
The patent applies preliminary action by fixing the terminal conductors to the insulating cover before the ultrasonic joining process. The fixing member is attached to the insulating cover at a position that prevents the terminal conductors from dispersing during subsequent handling and joining operations, ensuring stable positional arrangement from the outset.
Solution Approach 2:
The fixing member acts as an intermediary element between the terminal conductors and the insulating cover. This intermediary component provides a mechanical connection that stabilizes the terminal conductors' positions relative to the insulating cover, preventing dispersion while allowing the ultrasonic joining process to proceed effectively.
2Stability of the object's composition
If fixing member is attached to insulating cover to prevent conductor dispersion, then positional arrangement is stabilized, but device complexity increases
Solution Approach 1:
The fixing member serves multiple functions: it attaches to the insulating cover to provide stable positioning for the terminal conductors, and it is positioned to allow effective ultrasonic joining. This multi-functionality reduces the need for separate positioning mechanisms, thereby limiting the increase in device complexity.
Solution Approach 2:
The insulating cover itself serves as part of the fixing mechanism by providing the surface to which the fixing member is attached. The insulating cover's structure is utilized to support the fixing function, reducing the need for additional complex supporting structures and keeping the overall device complexity manageable.
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 efficient production of joined electric cables by preventing conductor dispersion, improving work efficiency and reducing waste through the use of discarded insulating cover portions as fixing elements.
Implementation Method 1
a method by which 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
Implementation Method 2
a method by which 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
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AI summary
Provided is an electric cable connection method for joining terminal conductors in an assembled state and a joined electric cable. 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 establish conductivity. 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 (20) 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).