Concave Sonotrode for Cable Sheath Joining
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Solution Overview
Problem
Existing sonotrodes cause surface damage and deformation when producing welded or soldered connections between cables and sheaths due to their design, leading to contact problems and rapid wear, especially in nickel-plated tubular cable lugs.
Innovation Solution
A sonotrode with concavely curved working faces that act in a self-centering manner, allowing for the production of joints without clamping the sheath to an anvil, and featuring smooth surfaces to reduce friction and wear, enabling the use of ultrasonic vibrations for connecting cables and sheaths without surface deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the working faces of the sonotrode and anvil are structured to prevent relative movement during connection, then connection stability is improved, but surface damage and deformation of the components increase
Solution Approach 1:
The working face of the sonotrode is designed with a concave curvature instead of a flat or structured surface. This curved geometry allows the working face to conform to the cylindrical shape of the cable lug, distributing the connection forces evenly across the surface and preventing localized stress concentrations that cause surface damage and deformation.
2Reliability
If structured working faces are used to prevent relative movement, then connection reliability is improved, but wear of the working face and anvil increases rapidly
Solution Approach 1:
The concave curved working face distributes mechanical stresses evenly during the connection process, reducing peak loads on any single point of the sonotrode surface. This even distribution of forces significantly reduces wear on the working face, extending the sonotrode's operational life while maintaining reliable connections.
3Strength
If high pressure is applied during connection to ensure proper contact, then connection strength is improved, but heat development and surface damage increase
Solution Approach 1:
The concave curvature of the working face increases the contact area between the sonotrode and the cable lug during connection. This larger contact area distributes the applied pressure more evenly, reducing peak stresses and minimizing heat generation while still achieving strong connections.
Solution Approach 2:
The invention changes the geometric parameter of the working face from flat or structured to concave curved. This geometric modification alters the pressure distribution pattern during connection, spreading forces over a larger area and reducing both peak pressure and associated heat development.
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 solution allows for the production of stable joints between cables and sheaths with reduced surface damage and wear, enhancing the connection quality and extending the sonotrode's lifespan by minimizing friction and heat development during the connection process.
Implementation Method 1
a sonotrode (1) connected to an ultrasonic source (8) at least at a connecting face (5)
Implementation Method 2
The cable (17) is plugged into the metal sleeve (12). The cable (17) is partially melted by means of ultrasonic vibrations
Implementation Method 3
the working face (2) be concavely curved at least sectionally in a second profile. As a result of the concave curvature, proposed according to the invention, of the working face (2) in a second profile, the sonotrode (1) acts in a 'self-centering' manner
Implementation Method 4
featuring smooth surfaces to reduce friction and wear
Data Source
AI summary
A sonotrode (18) for producing a welded and/or soldered join between a cable (17) and a sheath (17), covering the cable (17), comprising at least one working surface (2). The working surface (2) is curved in a concave manner, at least in sections. An anvil (10) comprises at least one counter surface (11) which is curved in a concave manner, at least in sections. The device for producing the join between a cable (17) and a sheath (17), covering the cable (17), comprises a sonotrode (18) joined to an ultrasound source (8) at least at a joining surface (5), and comprising an anvil (10) arranged opposite the working surface (2) of the sonotrode (18). A method for producing a join between a cable (17) and a sheath (17) covering the cable (17) is also disclosed.