Core Wire Tip Joining with a Tubular Jig for Shape Control
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Solution Overview
Problem
Conventional electric wire manufacturing methods struggle to control the shape of solidifying melted core wires, leading to variations in electric wire performance.
Innovation Solution
An electric wire manufacturing method and apparatus that uses a tubular jig to hold a core wire with a gap between its inner wall and the core wire's outer surface, where laser light is emitted axially to melt and integrate the strands, forming a joined portion that fills the gap, allowing for precise control over the shape of the solidified core wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser welding is used to melt and join core wire strands, then the strands can be integrated, but the shape of the solidifying melted core wire cannot be controlled, leading to performance variations
Solution Approach 1:
A transparent jig is introduced as an intermediary component between the laser beam and the core wire. The jig has a tubular shape with an inner diameter larger than the core wire outer diameter, creating a gap that allows the melted core wire to solidify in a controlled manner while the laser beam passes through the transparent jig to melt the strands. This intermediary structure enables shape control without interfering with the laser welding process.
Solution Approach 2:
The invention changes the physical parameters of the welding environment by introducing a transparent jig that modifies the space around the core wire. By controlling the gap between the jig inner wall and the core wire outer surface, the solidification shape of the melted core wire can be precisely controlled, transforming the uncontrolled melting process into a controlled shaping process.
2Ease of manufacture
If the core wire is placed tightly against the jig inner wall, then positioning is simplified, but the melted substance cannot fill the gap effectively to form a controlled joined portion
Solution Approach 1:
The jig is designed with specific local characteristics: a tubular shape with a predetermined inner diameter that is intentionally larger than the core wire outer diameter. This creates a controlled gap region where the melted substance can flow and solidify to form the joined portion. The local quality of the jig's internal geometry directly enables the gap-filling mechanism that controls the joined portion shape.
3Manufacturing precision
If a transparent jig is used to transmit laser light, then shape control is achieved, but the device complexity increases
Solution Approach 1:
The transparent jig serves multiple functions simultaneously: (1) it acts as a container that defines the shape of the joined portion, (2) it transmits the laser beam to melt the core wire strands, and (3) it maintains the gap between the core wire and the jig wall. This multi-functionality reduces the need for additional components, offsetting the complexity introduced by the transparency requirement.
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
This method effectively controls the shape of the solidifying melted core wire, reducing performance variations and improving electrical performance by forming a joined portion that extends along the axial direction, facilitating consistent and improved electric wire assembly.
Implementation Method 1
emitting laser light toward a tip of the core wire placed inside the jig
Implementation Method 2
the laser light being emitted in an axial direction of the core wire... forming a joined portion that integrates the strands
Implementation Method 3
integrating the tips through melting by surface tension of the molten metal
Data Source
AI summary
An electric wire manufacturing method includes: a step of placing a core wire including a plurality of strands inside a tubular jig; and a step of forming a joined portion that integrates the strands by emitting laser light along an axial direction of the core wire toward a tip of the core wire placed inside the jig. In the placing step, the core wire is placed with a gap between an inner wall surface of the jig and an outer circumferential surface of the core wire while the tip of the core wire faces upward relative to a horizontal line. In the step of forming the joined portion, the joined portion is formed by filling the gap with a melted substance of the strands.