Terminal-Formed Electric Wire Manufacturing Using Low-Melting Intermediary
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Solution Overview
Problem
Conventional methods for manufacturing terminal-formed electric wires face challenges in achieving desired terminal shapes due to the need to heat the core wire above its melting point, which can result in incomplete melting and difficulty in forming the desired shape.
Innovation Solution
A method involving the use of a welding member with a lower melting point than the core wire, placed at the terminal-forming target portion, which is melted and solidified under electrical conduction and pressure to form the desired terminal shape, while also filling gaps between strands to enhance strength and reduce cavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the core wire is heated to a temperature higher than its melting point for terminal forming, then the core wire can be melted and formed into a terminal shape, but the core wire may not be perfectly melted due to its high melting point, making it difficult to form the desired terminal shape
Solution Approach 1:
A welding member made of metal with a lower melting point than the core wire is introduced as an intermediary substance. This welding member is placed at the terminal-forming target portion of the core wire, allowing it to melt first and facilitate the forming process at a lower temperature than required for direct core wire melting.
Solution Approach 2:
The invention changes the melting point parameter of the material at the terminal-forming portion by introducing a welding member with a lower melting point than the core wire. This parameter change enables the terminal forming process to occur at a lower temperature, improving manufacturability while maintaining the desired terminal shape.
2Temperature
If high conduction currents and extended conduction times are used to melt the core wire, then the core wire can be heated to melting temperature, but the manufacturing cost increases and the process becomes less efficient
Solution Approach 1:
By introducing a welding member with a lower melting point, the invention changes the temperature parameter required for the terminal forming process. This parameter change reduces the heating temperature needed, which in turn reduces the conduction current and time required, thereby improving manufacturing efficiency and productivity.
Solution Approach 2:
The welding member acts as a mediator that absorbs the heating energy at a lower temperature threshold. This intermediary approach reduces the energy input requirements compared to directly heating the core wire to its high melting point, improving the overall energy efficiency and productivity of the manufacturing 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
This approach allows for the formation of terminal-formed electric wires with improved strength and reduced manufacturing costs by avoiding the need for high conduction currents and extended conduction times, while ensuring the desired terminal shape and strength are achieved.
Implementation Method 1
at least the welding member in the terminal-forming target portion is melted by electrically conducting the pair of electrodes while pressing the terminal-forming target portion with the pair of electrodes
Implementation Method 2
melted metal is solidified by stopping electric conduction to the pair of electrodes
Data Source
AI summary
A method of manufacturing a terminal-formed electric wire includes a welding member placing process in which at least one welding member formed of metal having a melting point lower than that of a plurality of metal strands included in a core wire is arranged to the core wire of at least a terminal-forming target portion of the electric wire, and a terminal forming process in which the exposed terminal-forming target portion is interposed between first and second electrodes having a shape corresponding to a desired terminal shape, at least the welding member in the terminal-forming target portion is melted by electrically conducting the first and second electrodes while pressing the terminal-forming target portion with the first and second electrodes, and the melted metal is then solidified, so that the terminal-forming target portion is formed as a terminal portion having a desired terminal shape.