Swaging Connection Structure for Tubular Metal Foil
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Solution Overview
Problem
Conventional swaging connection structures using tubular braided members are large and heavy, making them unsuitable for weight-saving applications in modern vehicles, and tubular metal foil members are prone to breaking when swaged, leading to reduced reliability and strength in electrical connections.
Innovation Solution
A swaging connection structure that uses a deformable ring-shaped swaging member with edgeless deformed parts to connect a tubular metal foil member and a tubular connection part, allowing for two-step swaging to ensure secure mechanical and electrical connections without edge-induced breakage, utilizing a first deformed part for weak swaging and a second deformed part for strong swaging to distribute tension effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a tubular metal foil member is used to substitute for the tubular braided member, then weight is reduced, but the member becomes easier to break during swaging and under tension
Solution Approach 1:
The ring-shaped swaging member is designed with differentiated local properties: the first deformed part has a larger radius of curvature for gentle contact over a wide area, while the second deformed part has a smaller radius of curvature for concentrated contact. This local quality differentiation allows the swaging member to apply distributed pressure that avoids stress concentration on the metal foil member, preventing breakage while achieving secure connection.
Solution Approach 2:
The ring-shaped swaging member is pre-formed with two deformed parts having different radii of curvature before the swaging process. This preliminary action ensures that during connection, the first deformed part makes initial contact to distribute stress, followed by the second deformed part for final securing, thereby preventing breakage during the connection process.
2Strength
If the ring-shaped swaging member is strongly swaged to secure connection, then connection strength is improved, but the metal foil member becomes more prone to breakage
Solution Approach 1:
The swaging member incorporates two deformed parts with different radii of curvature to create localized contact zones. The first deformed part with larger radius provides gentle, distributed contact to prevent breakage, while the second deformed part with smaller radius provides concentrated contact for strong connection. This local quality differentiation resolves the contradiction between connection strength and breakage resistance.
Solution Approach 2:
The connection is achieved through partial action of two deformed parts rather than uniform strong swaging across the entire circumference. The first deformed part applies sufficient pressure for connection while the second provides additional securing, avoiding excessive force that would cause breakage of the metal foil member.
3Ease of manufacture
If the shield ring is punched by press to form ring circumference, then the ring shape is created, but edges are induced that may cause breakage of the metal foil member
Solution Approach 1:
The punching process that creates edges is converted into a beneficial feature by designing the first deformed part with a larger radius of curvature that contacts the metal foil member over a wide area. This design ensures that even if edges are present on the punched ring, the distributed contact pressure prevents stress concentration at edge locations, converting the potential harm of edges into a non-issue through geometric design.
Solution Approach 2:
The radius of curvature parameter of the first deformed part is increased to create a gentler contact surface. This parameter change transforms the interaction between the swaging member and metal foil member, ensuring that edge features from punching do not create stress concentration points that would lead to 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 solution enhances connection reliability and strength, minimizes breakage risks, and allows for the use of conventional equipment, ensuring stable electrical and mechanical connections while reducing the weight of components.
Implementation Method 1
a metallic ring-shaped swaging member deformable by swaging... both formed inwardly into edgeless shape by swaging the ring-shaped swaging member from its outside to inside
Data Source
AI summary
A swaging structure is provided with a tubular metal foil member made of metal foil. The swaging connection structure is the one that a ring-shaped swaging member is swaged so as to include an area of main contact with a plurality of points or plurality of lines and an area of main contact with area, and thereby to electrically and mechanically contact the tubular metal foil member and a tubular connection part. The swaging connection member is also made a connection structure arranged such that an edge of a circumferential edge part of the ring-shaped swaging member is arranged not to contact with the tubular metal foil member.