Laser Welding Terminal Wire with Absorbing Layer
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Solution Overview
Problem
Conventional terminal-attached electric wire coupling structures require improvement in the coupling between electric wires and terminals, as they do not ensure a secure and efficient electrical connection.
Innovation Solution
A method involving an electric wire with a core wire made of element wires and a terminal with barrel pieces that wrap around the core wire, forming a slit for laser welding to bond the element wires to the conductor coupling part, ensuring a secure electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conventional coupling structure is used with laser melting, then the element wires are bonded to the terminal, but the element wires scatter during laser irradiation and the coupling reliability is insufficient
Solution Approach 1:
The patent introduces a laser absorbing layer as an intermediary substance between the element wires and the laser beam. This layer absorbs the laser energy and converts it to heat, which then melts the element wires for bonding. The absorbing layer prevents direct laser irradiation on the element wires, thereby preventing wire scattering while achieving reliable bonding through controlled melting and adhesion.
2Object-affected harmful factors
If additional holding jigs are used to prevent wire scattering, then the wire scattering is controlled, but the manufacturing process becomes more complex
Solution Approach 1:
The patent makes the terminal structure itself serve the dual function of both coupling and preventing wire scattering. The laser absorbing layer is integrated into the terminal's conductor coupling part, eliminating the need for separate holding jigs. The terminal structure provides its own support and positioning functions through the integrated absorbing layer design.
Solution Approach 2:
The patent extracts the wire scattering prevention function from the terminal structure itself and implements it through the integrated laser absorbing layer. This eliminates the need for external holding jigs while maintaining the terminal's primary coupling function. The absorbing layer is applied directly to the conductor coupling part, creating a self-contained solution.
3Strength
If the element wires are directly melted by laser, then the bonding is achieved, but the wires scatter during the process
Solution Approach 1:
The laser absorbing layer serves as a mediator that intercepts the laser beam before it directly hits the element wires. The layer absorbs the laser energy and converts it to thermal energy, which then conducts heat to melt the element wires. This indirect heating method prevents wire scattering while achieving the necessary melting temperature for strong bonding between the wires and terminal.
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 enhances the coupling between the electric wire and terminal, providing a strong and reliable electrical connection without the need for additional holding jigs, while preventing the scattering of element wires during laser irradiation.
Implementation Method 1
melting the element wires of the core wire by emitting laser light toward the core wire through the slit
Implementation Method 2
the element wires melted with the laser light are bonded to the conductor coupling part
Data Source
AI summary
A method of manufacturing a terminal-attached electric wire includes: installing an electric wire including a core wire including a plurality of element wires to a terminal having a conductor coupling part having a pair of barrel pieces, the core wire being installed between the pair of barrel pieces; bending the pair of barrel pieces to cause the pair of barrel pieces to wrap around and cover the core wire in a circumferential direction to form a slit extending in an axial direction between the pair of barrel pieces, with respect to the circumferential direction; melting the element wires of the core wire by emitting laser light toward the core wire through the slit; and adhering the element wires melted with the laser light to the conductor coupling part.