Electromagnetic Shield Component Welding with Crystal Refining Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electromagnetic shield components for wire harnesses face issues with crystal grain coarsening during welding, which can lead to potential breakage at the welded portions.
Innovation Solution
Incorporating connectors with a crystal refining agent between half-split tubes, which are welded together, to prevent crystal grain coarsening and ensure a strong, stable connection while maintaining the shape of the tubes during the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If two half-split tubes are welded to each other to allow wire insertion after connector attachment, then ease of operation is improved, but crystal grains in the welded portion become coarse leading to reduced strength
Solution Approach 1:
A filler material is introduced as an intermediary substance during the welding process of half-split tubes. This filler material refines the crystal grains in the welded portion, preventing coarsening that would otherwise occur during welding. The filler material acts as a mediator between the two half-split tubes, enabling strong welding while maintaining fine crystal grain structure and thus high strength in the welded joint.
2Device complexity
If welding is performed on half-split tubes to join them, then device complexity is reduced, but crystal grain coarsening occurs making the welded portion prone to breakage
Solution Approach 1:
The filler material serves as a mediator during welding, refining crystal grains in the welded portion of half-split tubes. This prevents the welded portion from becoming prone to breakage due to crystal grain coarsening, thereby maintaining high reliability while keeping the device structure simple through welding.
Solution Approach 2:
The filler material changes the thermal and metallurgical parameters during the welding process. By controlling crystal grain growth through the filler material, the welding process produces fine-grained, high-strength joints rather than coarse-grained, weak joints. This parameter change ensures reliable welded portions that resist breakage.
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 use of crystal refining agents in connectors between half-split tubes prevents crystal grain coarsening, enhancing the structural integrity of the electromagnetic shield component and reducing the risk of breakage, while allowing for precise welding that maintains the original shape of the tubes.
Implementation Method 1
a plurality of connectors that contain a crystal refining agent, and are provided between, and are welded to, the two first ends of the first half-split tube in the circumferential direction and the two second ends of the second half-split tube in the circumferential direction
Implementation Method 2
connectors that contain a crystal refining agent, and are provided between, and are welded to, the two first ends of the first half-split tube
Data Source
AI summary
An electromagnetic shield component that includes a tube that is electrically conductive and has an internal space through which an electrical wire is to be inserted, wherein the tube includes: a first half-split tube that has a half-split tubular shape and has two first ends in a circumferential direction; a second half-split tube that has a half-split tubular shape and has two second ends in the circumferential direction that are provided so as to face the two first ends of the first half-split tube in the circumferential direction; and a plurality of connectors that contain a crystal refining agent, and are provided between, and are welded to, the two first ends of the first half-split tube in the circumferential direction and the two second ends of the second half-split tube in the circumferential direction.