Stepped Terminal for Ultrasonic Welding of Mixed Wire Thicknesses
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Solution Overview
Problem
Existing terminal-wire assemblies face issues when connecting multiple wires of different thicknesses, as ultrasonic welding can lead to incomplete connections due to uneven distribution of ultrasonic waves, particularly when thicker wires concentrate the waves, affecting the connection of thinner wires.
Innovation Solution
A stepped connecting portion on the terminal allows wires with different thicknesses to be connected side by side, with the thinner conductor wire positioned at a higher level on the connecting portion, reducing the step between welding surfaces and enabling even ultrasonic welding, thus minimizing the difference in compression ratios across wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a plurality of wires including conductors having different thicknesses are arranged side by side and welded at once, then welding efficiency is improved, but ultrasonic waves are concentrated on the wire having a thicker conductor causing incomplete connection of the wire having a thinner conductor
Solution Approach 1:
The connecting portion is designed with a stepped structure that introduces a vertical dimension to compensate for horizontal thickness differences. By positioning the thinner wire on a higher step and the thicker wire on a lower step, the welding surfaces are aligned at the same level, enabling uniform ultrasonic wave distribution across all wires during simultaneous welding.
Solution Approach 2:
Each wire is positioned on a specific step of the connecting portion according to its thickness. The stepped structure provides locally adapted positioning where thinner wires occupy higher steps and thicker wires occupy lower steps, ensuring that each wire's welding surface aligns with the others despite thickness variations.
2Manufacturing precision
If wires are connected one by one to the terminal, then connection quality is maintained, but the connected state of previously connected wires is adversely affected by ultrasonic welding vibration
Solution Approach 1:
Multiple wires are connected to the terminal in a single simultaneous welding operation rather than sequentially. The stepped connecting portion enables all wires to be positioned and welded together at once, eliminating the adverse effects of ultrasonic vibration on previously connected wires while maintaining high connection quality through proper surface alignment.
3Manufacturing precision
If a stepped connecting portion is used to align welding surfaces, then ultrasonic welding uniformity is improved, but device complexity increases
Solution Approach 1:
The connecting portion is segmented into multiple steps or levels, each designed to accommodate wires of specific thicknesses. This segmentation creates distinct positioning zones that simplify wire arrangement and ensure proper alignment, making the manufacturing process more straightforward despite the stepped geometry.
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 configuration ensures equal and reliable connectivity of wires with varying thicknesses, facilitating a simple and cost-effective method for assembling terminal-wire assemblies by ensuring consistent welding across all wires.
Implementation Method 1
the plurality of wires including the conductors having different thicknesses are connected to the connecting portion by ultrasonic welding
Implementation Method 2
ultrasonic welding vibration
Data Source
AI summary
A terminal (20) includes a connecting portion (24) to which a plurality of wires (11, 12) including conductors (13, 14) having different thicknesses are to be connected side by side, and the connecting portion (24) is stepped. A terminal-wire assembly (10) includes a plurality of wires (11, 12) including conductors (13, 14) having different thicknesses and a terminal (20) including a connecting portion (24) to which the plurality of wires (11, 12) are to be connected side by side, and the connecting portion (24) is stepped. In the terminal-wire assembly (10), the wire (12) connected at a high position on the connecting portion (24) includes the thinner conductor (14) than the wire (11) connected at a low position on the connecting portion (24).