Connector Housing Laser Access for Multi-Row Terminal Welding
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Solution Overview
Problem
Existing connector technologies face challenges in efficiently welding terminals and electric wires within a connector housing, particularly when a large number of wires are accommodated, leading to complex assembly processes and limitations in automatic operation.
Innovation Solution
A connector device with a connector housing featuring laser radiation through holes in its side walls, allowing for laser welding of terminals and electric wires within the housing without the need for large openings or special tools, enabling efficient welding even when terminals are arranged in multiple rows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure welding is performed using a welding machine with a large electrode, then welding of terminals and electric wires can be achieved, but large openings must be provided in the connector housing and the structure becomes complex
Solution Approach 1:
The patent replaces the mechanical pressure welding system (requiring large electrodes and complex housing openings) with a laser welding system. The laser beam can penetrate through the terminal accommodating chamber wall to weld terminals and electric wires from the inside, eliminating the need for large openings and complex external welding equipment.
Solution Approach 2:
The patent introduces the terminal accommodating chamber wall as an intermediary structure that allows laser transmission. The wall is designed with laser transmission properties, enabling the laser beam to pass through it and reach the welding position inside the chamber, thus avoiding the need for large openings in the housing.
2Quantity of substance
If terminals and electric wires are arranged in multiple rows to accommodate many wires, then connector capacity increases, but arranging welding tools becomes difficult and automatic operation is limited
Solution Approach 1:
The patent replaces the mechanical welding tool arrangement system with a laser welding system. The laser beam can be precisely directed and focused on multiple welding positions within the terminal accommodating chamber, making it easy to weld terminals and electric wires arranged in multiple rows without complicating tool arrangement.
Solution Approach 2:
The laser welding system performs welding operations automatically by radiating the laser beam through the terminal accommodating chamber wall to predetermined positions. This enables automatic operation for welding multiple terminals and electric wires arranged in various configurations, eliminating the need for complex manual tool arrangement.
3Ease of operation
If large openings are provided in the connector housing for welding, then welding access is improved, but the housing structure becomes complex and automation is hindered
Solution Approach 1:
The patent uses the terminal accommodating chamber wall as an intermediary that transmits laser beams. This wall structure allows welding access without requiring large openings, as the laser can penetrate through the wall material itself, maintaining housing integrity while enabling welding operations.
Solution Approach 2:
The patent substitutes the mechanical approach of providing large physical openings for welding access with an optical approach using laser beams. The laser can pass through the terminal accommodating chamber wall, providing welding access without compromising the housing structure or requiring complex modifications.
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 facilitates efficient welding of terminals and electric wires within the connector housing, simplifying the assembly process, enabling easier automation, and reducing manufacturing costs, while avoiding complications in arranging tools for welding.
Implementation Method 1
a laser radiation through hole is formed in side walls, each forming the terminal accommodating chambers, the laser radiation through hole being configured to allow the plurality of terminals and the plurality of electric wires to be welded with each other inside the terminal accommodating chambers, and the laser radiation through hole is configured to allow laser light emitted from a laser welding machine disposed outside the connector housing to enter one of the plurality of terminal accommodating chambers
Data Source
AI summary
A connector device includes a connector housing including a plurality of terminal accommodating chambers, a plurality of terminals accommodated in the plurality of terminal accommodating chambers, and a plurality of electric wires configured to be welded to the respective one of the plurality of terminals. A laser radiation through hole is formed in side walls, each forming the terminal accommodating chambers, the laser radiation through hole being configured to allow the plurality of terminals and the plurality of electric wires to be welded with each other inside the terminal accommodating chambers, and the laser radiation through hole is configured to allow laser light emitted from a laser welding machine disposed outside the connector housing to enter one of the plurality of terminal accommodating chambers.