Corrugated Joined Conductor Structure for Stronger Ultrasonic Welding
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Solution Overview
Problem
Existing joined conductors have weaker joining strength between conductors arranged in the left-right direction compared to those in the up-down direction, which affects the electrical conductivity and rigidity of the conductor bundles.
Innovation Solution
A joined conductor with a corrugated portion on its surface, featuring convex and concave lines that protrude and recess respectively, is formed through ultrasonic welding, enhancing the contact area and strength between conductors aligned in the left-right direction, and a conductor joining device with similar corrugated features on its surfaces to improve the joining process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conductors are joined by ultrasonic welding while pressurizing from the thickness direction, then joining strength in the up-down direction is sufficient, but electrical conductivity between conductors deteriorates
Solution Approach 1:
The corrugated portions with increased surface area improve the contact between conductors in the left-right direction, providing multiple contact paths for electrical current flow. This enhanced contact area compensates for potential conductivity issues while maintaining the original pressurizing method that ensures sufficient up-down joining strength
2Strength
If corrugated portions are formed on facing surfaces with convex and concave lines, then joining strength and electrical conductivity improve, but device complexity increases
Solution Approach 1:
The corrugated portions are formed by relatively simple processes such as rolling or pressing operations that create wavy patterns on the conductor surfaces. These forming methods, while adding surface complexity, do not require complex multi-step manufacturing processes, thus limiting the increase in overall device complexity
Solution Approach 2:
The corrugated portions are formed only on the specific facing surfaces where joining occurs, rather than modifying the entire conductor structure. This localized approach adds complexity only where necessary for joining improvement, minimizing the overall increase in device complexity
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 significantly improves the joining strength and electrical conductivity between conductors, enhancing the rigidity and integrity of the joined conductor while reducing the risk of damage and ensuring reliable electrical connectivity.
Implementation Method 1
ultrasonically joining the conductors while pressurizing the conductors from a thickness direction
Data Source
AI summary
[Object]The present invention provides a joined conductor and a method for manufacturing a joined conductor that can improve electrical conductivity between conductors.[Solution]In a joined conductor 100 including a joining portion 110 in which a plurality of conductors exposed portions 220 arranged along a longitudinal direction X are fused and joined, the joining portion 110 is configured to have a substantially rectangular shape in an orthogonal cross section orthogonal to the longitudinal direction X, and among a pair of side surfaces in width direction 120 and a pair of side surfaces in up-down direction 130 configured such that a first surface 121 and a second surface 122 that face each other in the orthogonal cross section, and a horn 131 and a horn 132 are paired, on each of the first surface 121 and the second surface 122 of the pair of side surfaces in width direction 120 that are at least one pair, a corrugated portion 140 that has a corrugated shape and in which a ridge 141 protruding outward and a valley 142 recessed inward are alternately continuously provided along the longitudinal direction X is formed.