Conductive Member Hot-Pressing Die Inversion for Removal
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Solution Overview
Problem
In the production of conductive members using hot-pressing with dies, the melted metal strands often form clearance-shaped portions that hug the die, making it difficult to remove the crimp-receiving portion from the first die.
Innovation Solution
A conductive member production method using a die with a protruding portion having a recession-shaped depression and a recessed portion with inclined molding surfaces, where the metal strands are heated and pressed between the two dies, forming a weld portion with inclined surfaces that facilitate easier removal by generating a force component aiding separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal strands are hot-pressed using a die with clearance, then the metal strands are bonded together to form a weld portion, but the melted metal strands enter the clearance and harden to form a clearance-shaped portion that hugs the protruding portion of the first die, making it difficult to remove the crimp-receiving portion from the die
Solution Approach 1:
The patent inverts the conventional die structure by providing a protruding portion with a recession-shaped depression instead of a simple clearance. This inverted geometry causes the molded metal to form an inclined surface that generates a separating force component, reversing the harmful hugging effect into a beneficial separation effect that facilitates easy removal from the die
Solution Approach 2:
The patent changes the geometric parameters of the die protruding portion by introducing a recession-shaped depression with specific inclination angles. This parameter change transforms the molding surface geometry, causing the molded metal to form inclined surfaces that generate force components in the separation direction, thereby changing the removal characteristics from difficult to easy
2Strength
If heating temperature is increased to melt sheath portions for bonding, then the sheath portions melt and harden to bond metal strands, but the metal strands themselves may melt excessively, affecting their original hardness and workability
Solution Approach 1:
The patent precisely controls the heating temperature parameter to fall within a specific range that is sufficient to melt the sheath portions for bonding but remains below the melting point of the metal strands. This parameter control ensures the sheath portions undergo phase change for bonding while the metal strands maintain their original hardness and workability
Solution Approach 2:
The patent creates different thermal conditions for different parts of the conductive member: the sheath portions are heated to melting temperature for bonding, while the metal strands are protected from excessive heating. This local quality approach allows selective melting of sheath portions without affecting the metal strand properties
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 allows for the easy removal of the weld portion from the die by creating a force component that assists in separation, while maintaining the original hardness of the metal strands and suppressing excessive melting, thus improving workability and ease of production.
Implementation Method 1
a heating step of heating a weld portion formation region that is a portion, with respect to an extending direction, of a conductive member constituted by a plurality of metal strands that are woven into a tube shape or a plurality of metal strands that are woven into a sheet shape
Implementation Method 2
heating is performed at a temperate that is higher than a melting point of the sheath portions and lower than a melting point of the metal strands
Implementation Method 3
a pressing step in which the heated weld portion formation region is sandwiched between and pressed by the protruding portion of the first die and the recessed portion of the second die
Implementation Method 4
the depression including a molding surface that is inclined so as to gradually extend toward a leading end surface side while extending laterally from the depression
Data Source
AI summary
A conductive member production method is performed with use of a die that includes a first die and a second die. The first die includes a protruding portion having a recession-shaped depression formed in a leading end surface, the depression including a molding surface that is inclined so as to gradually extend toward the leading end surface side while extending laterally from the depression. The second die includes a recessed portion into which the protruding portion can be inserted. The method includes a heating step of heating a weld portion formation region that is a portion, with respect to an extending direction, of a conductive member constituted by multiple metal strands, and a pressing step in which the heated weld portion formation region is sandwiched between and pressed by the protruding portion of the first die and the recessed portion of the second die.