Litz Wire Termination Using Induction Heating After Crimping
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Solution Overview
Problem
Existing methods for connecting terminals to Litz wire require stripping or dipping individual strands, which are time-consuming, hazardous, and costly, and mechanical crimps often fail to make secure connections.
Innovation Solution
A crimping and induction heating process that forms an electrical connection by crimping Litz wire strands and then using induction heating to melt away insulation, allowing direct contact between conductors without the need for pre-treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical crimping is used to connect terminal to Litz wire, then connection speed is improved, but connection reliability deteriorates because crimp connections fail to make contact with each strand and break strands
Solution Approach 1:
The patent replaces the mechanical crimping system with an induction heating system. Instead of using mechanical force to compress and contact the strands, the invention uses electromagnetic induction to heat and melt the insulation, allowing the conductors to make electrical contact through the molten insulation medium. This substitution resolves the contradiction by eliminating the mechanical contact issues that caused both strand breakage and poor electrical contact.
Solution Approach 2:
The patent changes the physical state of the insulation material from solid to liquid through induction heating. By controlling the temperature parameter to melt the insulation rather than mechanically removing it, the process enables electrical contact between strands while preserving the conductor integrity. This parameter change resolves the contradiction by allowing reliable electrical connection without mechanical damage to the strands.
2Reliability
If insulation stripping or solder bath dipping is performed on individual strands, then electrical connection reliability is improved, but processing time increases and safety hazards occur due to outgassing
Solution Approach 1:
The patent merges multiple separate operations (insulation removal and electrical connection) into a single induction heating step. Instead of first stripping insulation from each strand and then making connections, the invention performs both functions simultaneously by heating the insulation in place to create electrical contact. This merging resolves the contradiction by achieving reliable electrical connection without the time-consuming sequential processes and associated safety hazards.
Solution Approach 2:
The patent uses molten insulation as an intermediary medium to achieve electrical contact. Rather than removing insulation to expose conductors, the melted insulation itself becomes the medium through which electrical connection is established. This intermediary approach resolves the contradiction by maintaining the insulation's protective function while enabling electrical connection, eliminating the need for time-consuming stripping operations.
3Reliability
If insulation stripping is performed on each strand, then electrical connection quality is improved, but manufacturing cost increases due to the complex and hazardous process
Solution Approach 1:
The patent replaces complex mechanical stripping and soldering systems with a simpler induction heating system. This substitution eliminates the need for specialized stripping equipment, solder baths, and associated safety infrastructure, thereby reducing manufacturing costs while maintaining or improving electrical connection quality through the molten insulation contact method.
Solution Approach 2:
The patent effectively makes the insulation at the connection point disposable by melting it to create the electrical connection. This approach is more cost-effective than using expensive mechanical stripping equipment and soldering materials, as the melted insulation serves its final purpose and is discarded, simplifying the overall manufacturing process and reducing equipment costs.
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
Provides a fast, safe, and cost-effective method to establish reliable electrical connections with Litz wire strands, eliminating the need for hazardous processes and ensuring comprehensive strand contact.
Implementation Method 1
The Litz wire termination portion is heated by an induction heating device after being crimped to the end of the Litz wire to heat the wire strands and melt away the insulators
Implementation Method 2
The induction heating device has an induction heating coil including an induction heating zone. The electrical contact assembly heats the Litz wire termination portion and the Litz wire
Implementation Method 3
heat the wire strands and melt away the insulators of the wire strands to electrically connect the conductors
Data Source
AI summary
An electrical connector assembly includes a Litz wire having multiple wire strands. Each wire strand has a conductor and an insulator. The electrical connector assembly includes an electrical contact having a contact portion at a mating end and a Litz wire termination portion at a terminating end. The contact portion is configured to make an electrical connection with a mating contact. The Litz wire termination portion is crimped to an end of the Litz wire. The Litz wire termination portion is heated by an induction heating device after being crimped to the end of the Litz wire to heat the wire strands and melt away the insulators of the wire strands to electrically connect the conductors at the end of the Litz wire to make an electrical connection with the individual wire strands of the Litz wire.