Parallel Wire Connection Structure for Precise Core Wire Alignment
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Solution Overview
Problem
Existing methods for connecting core wires in transmission cables result in misalignment due to bending stress, making high-density electrical connections difficult, and require replacement of all wires when defects occur, rather than just the defective ones.
Innovation Solution
A wire connection structure with a resin molded fixing member that aligns core wires parallel to each other, featuring a tearing portion for easy replacement of defective wires, and a sealing member for watertight connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wires are fixed by fixing means in conventional transmission cable manufacturing, then wires are held in position, but wires remain in a tilted state with bending stress causing misalignment when the wire guiding jig is removed
Solution Approach 1:
The fixing member is designed with a wire guiding portion that pre-aligns the wires in a parallel state before the resin molding process. This preliminary alignment action ensures that wires are positioned correctly before being permanently fixed, eliminating the need for subsequent realignment and preventing misalignment issues that occur when wires are fixed in a tilted state.
Solution Approach 2:
The fixing member changes the physical state of wire fixation from a tilted, stress-bearing state to a parallel, stress-free state. By modifying the alignment parameters and fixing geometry, the resin molded fixing member eliminates bending stress while maintaining precise parallel alignment of the wires.
2Ease of manufacture
If all wires are fixed together as a bundle, then positioning is simplified, but replacement of defective wires requires replacing all wires, reducing productivity
Solution Approach 1:
The fixing member is designed with individual fixing portions for each wire, allowing wires to be fixed separately rather than as a bundled group. This segmentation enables selective access to individual wires for replacement while maintaining the overall fixed structure, thus improving replacement efficiency without compromising positioning simplicity.
Solution Approach 2:
The fixing member provides different fixing characteristics for different wires through individual fixing portions. Each wire can be independently secured or accessed based on its specific requirements, allowing defective wires to be replaced without affecting the fixation of other wires, thereby enhancing productivity.
3Quantity of substance
If wire density is increased for high-density electrical connections, then connection capability is improved, but alignment precision becomes more difficult to maintain due to bending stress
Solution Approach 1:
The wire guiding portion of the fixing member pre-aligns multiple wires in a parallel configuration before resin molding. This preliminary alignment action ensures that even as wire density increases, all wires maintain their relative positions and parallelism, preventing misalignment issues that would otherwise occur with high-density packing.
Solution Approach 2:
The fixing member modifies the spatial parameters of wire arrangement by enforcing parallel alignment and eliminating bending stress. This parameter change allows wires to be densely packed while maintaining precise alignment, as the fixing member's geometry ensures proper positioning regardless of the number of wires.
Data Source
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AI summary
A wire connection structure for electrically connecting ends of a plurality of core wires, each of which is exposed by stripping a coating at an end region of each of a plurality of wires arranged in parallel, to terminals corresponding to the plurality of wires, includes a fixing member composed of a resin molded body that contacts outer circumference surfaces of the plurality of wires in a vicinity of the end region and fixes relative positions between the plurality of wires, with the plurality of wires being aligned parallel to each other in the vicinity of the end region, wherein a tearing portion that can be torn along a longitudinal direction of the wires for being extremely thin or is torn along the longitudinal direction is formed for each wire at a part of a region contacting the outer circumference surface.