Segmented Horn Chip for Ultrasonic Cable Busbar Joining
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Solution Overview
Problem
The ultrasonic joining method for cable assemblies faces issues with insufficient pressing force and ultrasonic vibration due to reaction forces and vibration leakage, leading to variations in the contact state between the core wire and busbar, resulting in inconsistent tensile strength at the joint surface.
Innovation Solution
A horn chip with two flat portions and a recessed portion is used to sandwich the core wire, allowing for effective ultrasonic vibration transmission while maintaining a space between the flat portions and the busbar, ensuring the core wire is pressed firmly without external interference, and the recessed portion's cross-sectional area is between 70% to 90% of the core wire's area to optimize the joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the welding horn is brought into contact with the busbar to press the core wire, then the core wire is pressed onto the busbar, but the reaction force from the busbar reduces the pressing force on the core wire and causes ultrasonic vibration leakage
Solution Approach 1:
The horn chip is segmented into multiple functional regions: a pressing portion that contacts the core wire, a busbar contact portion that contacts the busbar, and a spaced region between them. This segmentation allows the pressing force and ultrasonic vibration transmission paths to be separated, preventing the reaction force from reducing the pressing force and preventing ultrasonic vibration leakage through the busbar contact portion.
Solution Approach 2:
The horn chip acts as an intermediary element between the ultrasonic vibration source and the core wire-busbar joint. By designing the horn chip with specific geometry (pressing portion, busbar contact portion, and spaced region), it mediates the transmission of ultrasonic vibration to the core wire while maintaining adequate pressing force, without allowing vibration leakage through direct contact between the pressing portion and busbar.
2Strength
If the horn chip presses the core wire firmly onto the busbar, then the joint strength is improved, but the contact state varies due to manufacturing variation
Solution Approach 1:
The horn chip geometry parameters are optimized to ensure reliable joining. The pressing portion has a width and length that provide sufficient pressing force distribution, the busbar contact portion has appropriate dimensions for stable contact, and the spaced region maintains optimal distance. These parameter optimizations ensure that the pressing force and ultrasonic vibration are consistently transmitted to the core wire, achieving reliable joint strength with high repeatability despite manufacturing variations.
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 tensile strength of the joint surface by ensuring consistent pressing force and ultrasonic vibration application, reducing variation and improving the manufacturing repeatability of cable assemblies.
Implementation Method 1
giving an ultrasonic vibration on the core wire while pressing the core wire onto the busbar using a horn chip to join the core wire to the busbar
Data Source
AI summary
A busbar is placed on an anvil, and a core wire of a cable is placed on the busbar. While the core wire is pressed onto the busbar using a horn chip, ultrasonic vibration is given to the core wire to join the core wire to the busbar. The horn chip has two flat portions and a recessed portion located between the flat portions. When the core wire is pressed onto the busbar using the horn chip, each of the flat portions and the busbar sandwich a part of the core wire therebetween while the recessed portion and the busbar put a remaining part of the core wire therebetween. Each of the sandwiched parts of the core wire does not reach an outer end of the corresponding flat portion to leave a space between the corresponding flat portion and the busbar.