Ultrasonic Terminal Bonding via Curved Surface
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Solution Overview
Problem
Conventional terminal-equipped electric wires face issues with the conductor bonding to the terminal, leading to peeling off when force or moment is applied, and the manufacturing process is complicated due to the need for insulation barrel swaging.
Innovation Solution
A terminal-equipped electric wire design featuring a conductor bonding part and a sheath supporting part, where the conductor is ultrasonically bonded to the terminal, and the sheath is supported by the sheath supporting part without permanent distortion, preventing peeling and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conductor is bonded to a planar portion of the terminal, then the bonding process is simple, but the bonded portion peels off when force or moment is applied
Solution Approach 1:
The terminal surface is changed from a planar portion to a curved surface (convex or concave). This curvature increases the bonding area and provides mechanical interlocking, preventing the bonded portion from peeling off when force or moment is applied, while maintaining bonding process simplicity
2Reliability
If the insulation barrel portion is provided and swaged to hold the sheath, then peeling of the bonded portion is prevented, but the manufacturing process becomes complicated
Solution Approach 1:
The peeling prevention function is merged into the terminal structure itself through the curved surface design, eliminating the need for a separate insulation barrel portion. The curved surface simultaneously provides bonding area and mechanical interlocking, preventing peeling without additional components or swaging processes
3Ease of manufacture
If multiple strands and terminal are clamped between anvil and horn for ultrasonic bonding, then bonding is performed, but bonding of the conductor to the terminal is not ensured
Solution Approach 1:
The terminal surface is designed with a curved portion (convex or concave) at the specific bonding location. This localized curvature concentrates the ultrasonic bonding energy and provides mechanical interlocking, ensuring reliable conductor to terminal bonding while maintaining ease of manufacture through the standard clamping process
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 design effectively prevents conductor peeling from the terminal and simplifies the manufacturing process by eliminating the need for swaging, ensuring reliable bonding and reduced manufacturing complexity.
Implementation Method 1
a portion of a conductor which is not covered with the sheath, and a part of the terminal are clamped between an anvil and a horn, and the horn is ultrasonically vibrated, thereby bonding the conductor of the electric wire to the terminal (ultrasonic bonding)
Data Source
AI summary
A terminal-equipped electric wire includes a terminal and an electric wire. The terminal includes a conductor bonding part and a sheath supporting part. The electric wire includes a conductor formed of a plurality of strands and a sheath covering the conductor such that the conductor is exposed to a predetermined length. The conductor exposed from the sheath is bonded to the conductor bonding part, and the sheath is supported by the sheath supporting part and is fixed in the terminal. The sheath supporting part is in a state where there is no permanent distortion with respect to a state when the terminal is present alone.