Laser Welded Terminal Box Suppresses Vibration During Ultrasonic Bonding
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Solution Overview
Problem
In the process of ultrasonic bonding of electric wires with metal terminals, vibrations transmitted through the electric wire can excessively affect the spring component of the metal terminal, leading to potential damage due to its lower rigidity compared to other parts, which can result in fatigue and increased stress.
Innovation Solution
A method involving laser welding of opposed portions of the metal terminal's box portion to suppress vibration, combined with ultrasonic vibration application to the second core exposed portion of the electric wire, effectively reducing the impact of vibrations on the spring by stabilizing the box portion and minimizing relative motion between its components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic vibration is applied to bond electric wires, then bonding efficiency is improved, but vibration is transmitted to the spring component causing fatigue and potential damage
Solution Approach 1:
A vibration absorbing member is introduced as an intermediary component between the ultrasonic vibration source and the spring terminal. This mediator absorbs and dissipates the transmitted vibration energy, protecting the spring from fatigue while allowing the ultrasonic bonding process to proceed efficiently. The vibration absorbing member acts as a buffer that decouples the harmful vibration transmission path.
2Strength
If the box portion of the metal terminal is made more rigid to protect the spring, then vibration resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The metal terminal is divided into functionally distinct segments: the box portion maintains its original simple structure for easy manufacturing, while a separate vibration absorbing member handles the vibration protection function. This segmentation allows each component to be optimized independently - the box portion remains simple and manufacturable, while the vibration absorption capability is provided by the specialized additive component.
3Strength
If the spring rigidity is increased to withstand vibration, then vibration resistance is improved, but electrical connection performance deteriorates
Solution Approach 1:
The vibration absorbing member serves as a mediator that selectively filters mechanical vibration while allowing electrical functionality to remain unaffected. By placing this intermediary between the vibration source and the spring, the spring can maintain its original low rigidity and good electrical contact properties, while the mediator handles the mechanical shock and vibration protection.
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 laser welding step significantly reduces the displacement and stress on the spring, enhancing the durability and reliability of the metal terminal by minimizing the adverse effects of ultrasonic vibration, thereby improving the overall bonding process and reducing the risk of spring damage.
Implementation Method 1
laser welding step laser-welding opposed portions where parts of the single conductive board forming the box portion are opposed to each other
Implementation Method 2
ultrasonic vibration applying step applying ultrasonic vibration to the second core exposed portion
Data Source
AI summary
Provided is a method of manufacturing an electric wire with terminal formed by connecting a first core exposed portion of an electric wire to a metal terminal having a box portion that is formed by processing a single conductive board into a box shape and has an opening in which a counterpart terminal is inserted, and a spring inside the box portion. After laser-welding opposed portions where parts of the single conductive board forming the box portion are opposed to each other, applying ultrasonic vibration to a second core exposed portion of the electric wire is executed.