Terminal Fitting-Equipped Conductor With Resistance-Welded Braided Ends
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Solution Overview
Problem
Conventional terminal fittings with braided wires face issues of loose ends and flaring, leading to reduced tensile strength and unstable contact resistance when crimped, especially when a bare metal wire is caught between barrel pieces.
Innovation Solution
A terminal fitting-equipped conductor with a crimped metal braided portion where the wires are fused together using resistance welding to create stable crimped ends, and an insulating member, such as a heat-contraction tube, is used to maintain a predetermined curved shape for easy connection and prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a braided wire is used for connecting battery terminals, then good flexibility is achieved, but the metal wires easily become loose at end portions and the end portions easily become flared
Solution Approach 1:
The patent applies preliminary action by fusing the metal wires at the end portions of the braided wire before crimping the terminal fitting. This pre-fusion process prevents the wires from becoming loose or flared during subsequent crimping operations, thereby maintaining wire stability while preserving the flexibility of the braided structure.
2Ease of manufacture
If crimping is performed on the barrel portion of a terminal fitting with loose braided wire, then connection is achieved, but a bare metal wire may be caught between the front ends of the barrel pieces reducing tensile strength
Solution Approach 1:
The patent applies preliminary action by fusing the metal wires at the end portions before crimping. This pre-fusion ensures that during the crimping process, the wires remain consolidated and do not separate or flare, preventing bare metal wires from being caught between barrel pieces and thereby maintaining high tensile strength in the crimped connection.
3Ease of manufacture
If flared braided wire is crimped, then connection is achieved, but a stable crimped state is not obtained resulting in unstable contact resistance
Solution Approach 1:
The patent applies preliminary action by fusing the metal wires at the end portions before crimping the terminal fitting. This pre-fusion process ensures that the wires maintain their position and do not flare during crimping, resulting in a stable crimped state with consistent contact resistance and improved electrical connection reliability.
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 tensile strength and achieves stable contact resistance by preventing wire loosening and ensuring a secure crimped state, while the insulating member facilitates easy connection and maintains the metal braided portion's shape, improving manufacturing efficiency and reducing electrical resistance.
Implementation Method 1
the wires are fused to each other
Implementation Method 2
an insulating member, such as a heat-contraction tube, is used to maintain a predetermined curved shape
Data Source
AI summary
The present disclosure provides a terminal fitting-equipped conductor that has a high level of tensile strength and can achieve stable contact resistance. A terminal fitting-equipped conductor is a terminal fitting-equipped conductor to which a terminal fitting is attached by crimping an end portion of a flexible metal braided portion made of a plurality of metal wires braided together. The wires are fused to each other by resistance welding and a crimped portion is formed at the end portion of the metal braided portion. The crimped portion is crimped to a barrel portion with which the terminal fitting is provided. The wires are mutually bonded by being fused to each other, and fixed. As a result, the crimped state of the crimped portion to the barrel portion is stable.