Flush Contact Zone Cable Design for Laser Welding Miniaturization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Miniaturization of cables is impaired by the size of the contact zone required for ultrasound welding, as a minimum size is necessary for the sonotrode to produce a connection between the cable core and electrical conductor.
Innovation Solution
A cable design with a contact zone filled flush with the insulation surface allows for a smaller connection area, enabling laser welding and minimizing the cable's dimensions, while using an electrically conductive contact material to ensure both mechanical and electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasound welding is used to connect the cable core to the electrical conductor, then a reliable electrical connection is achieved, but the contact zone requires a minimum size that impairs cable miniaturization
Solution Approach 1:
The patent replaces ultrasound welding (mechanical vibration-based welding) with laser welding (optical energy-based welding). The contact zone is designed with a flush surface that allows direct laser beam application, eliminating the need for a large contact zone required by sonotrode placement in ultrasound welding. This substitution enables cable miniaturization while maintaining connection reliability.
2Volume of moving object
If the contact zone is made smaller to enable cable miniaturization, then cable size is reduced, but the ability to place a sonotrode for ultrasound welding is compromised
Solution Approach 1:
The patent replaces the mechanical sonotrode-based ultrasound welding system with a laser welding system. The flush surface design of the contact zone allows direct application of the laser beam to the exposed cable core, enabling welding of miniaturized cables without requiring space for sonotrode placement. This resolves the contradiction between cable size reduction and welding feasibility.
Solution Approach 2:
The patent transitions from a mechanical contact-based welding approach (requiring surface area for sonotrode placement) to a beam-based welding approach (laser). The flush surface design allows the laser beam to access the cable core from above without requiring lateral space, effectively changing the welding dimension from surface-area-dependent to beam-path-dependent, enabling miniaturization.
3Volume of moving object
If the contact zone surface is made flush with the cable surface, then cable miniaturization is enabled and deformation risk is reduced, but the welding method must be changed from ultrasound to laser welding
Solution Approach 1:
The patent systematically replaces ultrasound welding with laser welding as the primary joining method. The flush surface design is specifically optimized for laser beam application, allowing the laser to melt and fuse the cable core to the electrical conductor without interference from surrounding insulation. This substitution, while changing the welding process, enables significant cable size reduction and simplified manufacturing.
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 design allows for a more compact cable configuration with reduced deformation risk and improved connectivity options, enabling smaller welding points and enhanced flexibility in cable arrangement.
Implementation Method 1
By introducing high-frequency mechanical vibrations, the sonotrode produces resonation which can be transferred to the contact zone
Implementation Method 2
By virtue of the high frequency and the pressure, friction gives rise to an atomic connection between the contact zone and the electrical conductor
Implementation Method 3
it is consequently possible, at the contact zone 10, to keep the distance between the contact zone 10 and the electrical conductor 8 small and to connect the cable 1 to the electrical conductor 8 with laser welding methods
Data Source
AI summary
A cable includes a cable core formed of an electrically conductive material and an insulation at least partially encasing the cable core. The cable core is exposed in a contact zone in which the cable contacts an electrical conductor. A surface of the contact zone is filled substantially flush with a cable surface of the insulation.