Thermal-Sprayed Wire Terminal Joining for Lower Assembly Burden
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Solution Overview
Problem
Manual caulking of electric wires to terminals is labor-intensive and becomes increasingly burdensome as the number of wires to be joined increases.
Innovation Solution
An electric wire joining structure that uses thermal spraying to join electric wires to terminals through insertion holes, reducing operator burden, with the option of a tapered part design for enhanced tensile strength and cold spraying for improved film formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual caulking is used to join electric wires to terminals, then the joining process can be performed with simple equipment, but the operator burden increases significantly as the number of wires to be joined increases
Solution Approach 1:
The patent replaces the manual mechanical caulking process with a thermal spraying system that uses a spray nozzle to deposit molten or semi-molten material onto the terminal and wire assembly, automatically forming a joining part that secures the wires without requiring manual caulking operations
Solution Approach 2:
The patent changes the physical state of the joining material from solid (in manual caulking) to molten or semi-molten state through thermal spraying, allowing the material to flow and conform to the terminal and wire geometry, then solidifies to form a strong joining part
2Manufacturing precision
If manual caulking is used for each wire individually, then precise control over each joint is achieved, but the joining time increases significantly with the number of wires
Solution Approach 1:
The patent merges multiple individual joining operations into a single thermal spraying operation, where the spray nozzle deposits material simultaneously onto multiple wires and the terminal together, forming multiple joining parts in one continuous process rather than treating each wire separately
Solution Approach 2:
The thermal spraying process operates continuously, with the spray nozzle moving along the terminal and wires in a continuous stream of molten material deposition, eliminating the start-stop nature of manual caulking operations and maintaining continuous productive action throughout the joining process
3Productivity
If thermal spraying is used to join wires to terminals, then operator burden is reduced and productivity increases, but the process complexity and equipment requirements increase
Solution Approach 1:
The thermal spraying equipment is designed to perform multiple functions: heating and melting the joining material, propelling the molten material onto the workpiece, and forming the joining part all in one integrated system, reducing the need for separate equipment for each function
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 method significantly reduces operator burden, especially with large numbers of wires, by automating the joining process and providing a strong, durable connection through thermal spraying, while minimizing material usage and preventing oxidation.
Implementation Method 1
a joining part formed by thermal spraying, the joining part joining the one or more electric wires to the terminal
Implementation Method 2
the spray material is melted or heated to a semi-molten state
Implementation Method 3
the spray material is sprayed in a cold state without being melted or heated to a semi-molten state
Data Source
AI summary
The present invention provides an electric wire joining structure (80), an electric wire joining method, and a terminal (1), each of which allows a reduction in burden on an operator. The present invention includes: one or more electric wires (10); a terminal (1) including one or more insertion holes (7) for the respective one or more electric wires (10), the one or more electric wires (10) being inserted into the respective insertion holes (7); and a joining part (20) formed by thermal spraying, the joining part (20) joining the one or more electric wires (10) to the terminal (1) on a side on which the one or more electric wires (10) have passed through the respective one or more insertion holes (7).