Terminal-formed Wire Segmented Core Bending
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Solution Overview
Problem
The existing terminal-formed wire design faces challenges with increased bending force and reactive force when the core wire diameter grows, making the bending process difficult and size management hard, especially as the terminal part lengthens.
Innovation Solution
The terminal-formed wire divides the core wire's element wires into two, folding their ends back in different directions to form a connection hole, which reduces bending force and allows for bonding and solidification, thereby maintaining the wire's form and controlling terminal size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the core wire part diameter is increased, then the strength of the terminal part is improved, but the bending force of the root part becomes larger making the process harder
Solution Approach 1:
The core wire part is segmented into multiple element wires (first through fourth element wires) that are folded in different directions. This segmentation allows each individual wire to be bent more easily while collectively providing the required strength, resolving the contradiction between terminal strength and bending ease.
2Ease of manufacture
If the length of the core wire part exposed from the covering part is increased to cope with large bending force, then the bending process becomes easier, but the size of the terminal part becomes larger
Solution Approach 1:
Instead of extending the exposed core wire length in one dimension, the solution folds multiple element wires in different spatial directions (first and second directions for first two wires, third and fourth directions for last two wires). This dimensional approach achieves the required terminal strength and processability without increasing overall terminal size.
3Strength
If the core wire part is folded back to form the terminal part, then the terminal part can resist tension forces, but the reactive force of the core wire part becomes large making it hard to maintain the wire form
Solution Approach 1:
The core wire part is divided into multiple element wires that are folded in different directions. This segmentation distributes the reactive forces from tension loads across multiple individually folded wires, preventing any single wire from generating excessive reactive force that would distort the overall wire form, while still providing collective tension resistance.
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 facilitates easier bending and maintains the wire's pre-terminal form while reducing terminal size, enhancing strength against tension forces by distributing stress across bonded wires.
Implementation Method 1
the plurality of element wires is bonded with each other and solidified all over the element wires
Data Source
Figure 1~2
Figure 3
AI summary
A terminal-formed wire (1) includes a covered wire (7) obtained by covering an outer circumference of a core wire part (3) including a plurality of element wires with a covering part (5); and a terminal part (11) provided at a terminal of the covered wire (7) and terminal-formed with the core wire part (3) exposed from the covering part and with the core wire part (3) having a connection hole (9), wherein, at the terminal part (11), the plurality of element wires of the core wire part (3) are divided into two; and wherein leading ends of the divided plurality of the element wires (13), (15) are folded back toward a root part in different directions from each other to form the connection hole (9).