Terminal-Equipped Electrical Wire With Folded Element Wires
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Solution Overview
Problem
Conventional terminal-equipped electrical wires experience insufficient melting of core wires at the terminal portion due to poor heat generation, leading to elevated resistance among element wires.
Innovation Solution
The terminal portion is configured with divided sections of element wires, where the tips are folded back towards the base portion and a conductive member is interposed between them, allowing for improved heat generation using an electric resistance welder to ensure sufficient melting of the element wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the tips of element wires are folded back toward the base portion without a conductive member, then the structure is simpler, but heat generation is insufficient and element wires are not molten sufficiently
Solution Approach 1:
A conductive member (such as a metal sheet or plate) is introduced as an intermediary between the divided sections of the core wire at the terminal portion. This conductive member serves as a mediator that concentrates and generates heat more effectively under the electric resistance welder, enabling sufficient melting of the element wires without complicating the overall structure excessively.
Solution Approach 2:
The invention changes the physical state and electrical parameters at the terminal portion by introducing a conductive member with different electrical conductivity and thermal properties compared to the insulated core wire. This parameter change enables concentrated heat generation through the conductive member, solving the insufficient melting problem.
2Temperature
If element wires are bundled without division, then the structure is simpler, but heat is not easily generated and melting is insufficient
Solution Approach 1:
The core wire is divided into two or more divided sections at the terminal portion, creating a segmented structure. This segmentation, combined with the conductive member, facilitates better heat generation and distribution. The divided sections are arranged to face different directions, improving both heat generation and tensile strength.
Solution Approach 2:
The invention applies local quality by dividing the core wire only at the terminal portion where heat generation and melting are needed, while keeping the rest of the wire structure intact. This localized segmentation with a conductive member enables targeted heat generation without affecting the overall wire simplicity.
3Reliability
If the terminal portion uses conventional bundling, then manufacturing is simpler, but resistance among element wires is elevated
Solution Approach 1:
The conductive member acts as an intermediary that facilitates better electrical contact and heat distribution among the divided sections of the core wire. This mediator reduces resistance among element wires by ensuring uniform heating and proper melting, thereby improving reliability without significantly complicating the manufacturing process.
4Strength
If divided sections are folded back facing different directions, then strength against tensile force is improved, but the configuration becomes more complex
Solution Approach 1:
The divided sections of the core wire are folded back to face different directions, creating an asymmetric configuration. This asymmetric arrangement improves tensile strength by distributing mechanical stresses more effectively. The asymmetry is localized to the terminal portion, maintaining overall structural simplicity.
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 configuration reduces the resistance of the terminal portion by enhancing heat generation and providing improved strength against tensile forces through uniform heating and increased rigidity.
Implementation Method 1
the terminal portion is configured as the terminal by using an electric resistance welder... owing to the heating by the electric resistance welder through the conductive member
Implementation Method 2
a conductive member is arranged between the divided sections... heating by the electric resistance welder through the conductive member
Implementation Method 3
allowing the element wires to be molten sufficiently... improve the heat generation property of the terminal portion
Data Source
AI summary
A terminal-equipped electrical wire includes: a covered electrical wire in which an outer periphery of a core wire including a plurality of element wires is covered by a cover portion; and a terminal portion that is provided to an end portion of the covered electrical wire and that is configured as a terminal by exposing the core wire from the cover portion and providing a connection hole to the core wire. At the terminal portion, the element wires of the core wire are divided into two divided sections, the tip of each of the divided sections is folded back toward a base portion in order to form the connection hole, a conductive member is arranged between the divided sections, and a resistance welder is used to configure the terminal.