Electric Wire Connecting Terminal Using Folded and Welded Conductors
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Solution Overview
Problem
Existing methods for forming connecting terminals on electric wires, especially for high voltage cables, are inefficient as they either require large and costly components or struggle with entangling thick wire conductors, leading to potential strength shortages and separation issues during boring work.
Innovation Solution
The method involves folding back and resistance welding parallel wire conductors to create a connecting terminal with a through hole, enhancing strength and preventing separation, while allowing for easy formation and automation regardless of wire thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rotary brush is pressed against wire conductors to entangle them irregularly, then the connecting terminal can be formed integrally at the end of the electric wire, but this method is impossible for thick wire conductors like high voltage cables due to their high strength
Solution Approach 1:
The invention changes the fundamental approach from mechanical entanglement (rotary brush) to thermal bonding (resistance welding). By changing the parameter of the forming method from mechanical to thermal, the solution becomes applicable to both thin and thick wire conductors, resolving the adaptability issue while maintaining ease of manufacture.
2Strength
If wire conductors are welded to each other in parallel, then the connecting terminal gains strength, but there is a concern that separation may occur during boring work
Solution Approach 1:
The invention transitions from a two-dimensional parallel arrangement to a three-dimensional folded structure. By folding the wire conductors back and creating overlapping layers that are then welded, the structure gains dimensional complexity that prevents separation during boring operations while maintaining high binding force.
3Reliability
If terminal metal fitting is press-fitted to the end of the electric wire, then connection to counter terminal is achieved, but components become large-sized incurring increase of cost
Solution Approach 1:
The invention merges the wire conductors themselves to form the connecting terminal structure, eliminating the need for separate terminal metal fittings. By folding and welding the wire conductors into a block-like shape with integrated through holes, the solution achieves connection capability while reducing component size and cost.
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 approach improves the strength of the connecting terminal, reduces manufacturing costs, and simplifies the process by ensuring high binding force and preventing wire conductor separation during boring work, even with thick wires like high voltage cables.
Implementation Method 1
By applying resistance welding to a plurality of wire conductors stripped of the insulation cover and extended in parallel with each other, surfaces of the adjacent wire conductors are welded to each other
Data Source
AI summary
An electric wire with a connecting terminal and a method for manufacturing the electric wire are provided. The electric wire has a plurality of wire conductors and an insulation cover that covers the wire conductors. The plurality of wire conductors includes the connecting terminal to be connected to a counterpart component at an end of the electric wire at which the plurality of wire conductors is stripped of the insulation cover. The connecting terminal has a first portion of the plurality of wire conductors, a second portion of the plurality of wire conductors folded back on top of the first portion, the first portion and the second portion being welded to each other, and a through hole extending through the connecting terminal at a location where the first portion and the second portion are welded to each other.