Conductive Member Welded Outer Layer Terminal Crimping

Solution Overview

Problem

Existing terminal-equipped wires with braided metal strands face difficulties in crimping due to the rigidity of the swaging portion formed by welding, which prevents adequate attachment of terminals to the metal strands.

Innovation Solution

A conductive member comprising coated metal wires with a welded portion, where the outer layer is formed by welding the coated metal wires together, allowing the inner layer to untwine and be crimped, with a method involving a heating and pressing process to create a pliant inner layer for improved terminal attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the swaging portion is formed by welding metal strands together with resistance welding to create a rigid structure, then the structural integrity is improved, but the terminal cannot be crimped adequately to the metal strands

Engineering Contradiction:

Improvestructural integrityVSAvoidterminal crimping

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The conductive member is divided into two distinct regions: a welded portion where metal strands are bonded for structural integrity, and an unwelded portion where strands remain flexible for terminal crimping. This segmentation allows each region to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the conductive member are given different properties: the welded portion has high strength and rigidity for structural support, while the unwelded portion maintains flexibility and untwining capability for terminal attachment. This local differentiation resolves the contradiction between overall strength and local crimpability.

Inventive Principle:

Principle #3Local quality

2Strength

If the metal strands are firmly welded together to create a rigid swaging portion, then the welding strength is improved, but the metal strands lose their ability to untwine during crimping

Engineering Contradiction:

Improvewelding strengthVSAvoiduntwining capability

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The conductive member is divided into two distinct regions: a welded portion where metal strands are bonded for structural integrity, and an unwelded portion where strands remain flexible for terminal crimping. This segmentation allows each region to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the conductive member are given different properties: the welded portion has high strength and rigidity for structural support, while the unwelded portion maintains flexibility and untwining capability for terminal attachment. This local differentiation resolves the contradiction between overall strength and local crimpability.

Inventive Principle:

Principle #3Local quality

3Stability of the object's composition

If the outer layer is formed by welding coated metal wires together, then the structural stability is improved, but the inner layer must remain pliant to allow adequate crimping

Engineering Contradiction:

Improvestructural stabilityVSAvoidcrimping operation

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The conductive member is divided into two distinct regions: a welded portion where metal strands are bonded for structural integrity, and an unwelded portion where strands remain flexible for terminal crimping. This segmentation allows each region to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the conductive member are given different properties: the welded portion has high strength and rigidity for structural support, while the unwelded portion maintains flexibility and untwining capability for terminal attachment. This local differentiation resolves the contradiction between overall strength and local crimpability.

Inventive Principle:

Principle #3Local 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 solution enables effective crimping of terminals to the conductive member, increasing the contact area and allowing the terminal to be securely attached, while maintaining the shape and pliability of the metal strands, thus enhancing the attachment process.

Implementation Method 1

the plurality of metal strands are bonded together by a portion where the sheaths have melted and solidified

Methodology Applied

Scientific EffectMelting and solidification: Melting

Implementation Method 2

heating a welded portion formation region... from an outer circumference side at a temperature higher than the melting point of the sheaths and lower than the melting point of the metal strands

Methodology Applied

Scientific EffectThermal heating: Heating

Data Source

PatentUS10395793B2Conductive member, terminal-equipped conductive member, and method of manufacturing conductive member

Publication Date: 2019.08.27 SUMITOMO WIRING SYSTEMS LTD

AI summary

A terminal is crimped to a portion where a plurality of metal strands are welded. A conductive member is configured by a plurality of coated metal wires provided with a plurality of metal strands and with an electrically conductive sheath covering a circumference of each of the plurality of metal strands. The conductive member includes a welded portion, in which at least a portion in an extension direction of the plurality of coated metal wires is welded, and the welded portion includes an outer layer that is formed on an outer circumference side by welding the plurality of coated metal wires together, and at least a portion of the plurality of coated metal wires on an inner side of the outer layer is capable of untwining due to crimping a terminal.