Ultrasonic Cable Joining for Mixed-Diameter Core Wires
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Solution Overview
Problem
Conventional ultrasonic joining methods for electrical cables with core wires of different diameters often result in incomplete joining, particularly when core wires are aligned parallel to the ultrasonic vibration plane.
Innovation Solution
An electrical cable manufacturing method and apparatus that sets a specific interval between facing surfaces in a joining device, using a pressing member and a vibrating member to apply ultrasonic vibration while sandwiching core wires, ensuring the interval is larger than the maximum diameter and smaller than the sum of the maximum and minimum diameters of the core wires, preventing parallel alignment and ensuring proper joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If core wires are arranged in a conventional ultrasonic joining setup, then the joining process can be performed, but core wires with different diameters may align parallel to the ultrasonic vibration plane causing incomplete joining
Solution Approach 1:
The patent introduces a new spatial dimension by setting a specific interval distance between facing surfaces in the ultrasonic joining device. This interval, defined as larger than the maximum core wire diameter and smaller than the sum of maximum and minimum diameters, creates a geometric constraint that forces core wires to arrange in a staggered configuration rather than parallel alignment, thereby ensuring complete ultrasonic joining for core wires of different diameters
2Adaptability or versatility
If the interval between facing surfaces is set too small, then core wires with larger diameters can be accommodated, but core wires with smaller diameters cannot be properly joined
Solution Approach 1:
The patent defines a specific parameter range for the interval distance between facing surfaces, where the interval is larger than the maximum core wire diameter and smaller than the sum of maximum and minimum diameters. This parameter optimization ensures that core wires of varying diameters can be properly accommodated and joined without parallel alignment, achieving both adaptability and joining 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 method effectively joins core wires with different diameters by preventing parallel alignment, thereby ensuring complete and reliable bonding during the ultrasonic joining process.
Implementation Method 1
joining the core wires by using the vibrating member to apply ultrasonic vibration to the core wires
Data Source
AI summary
An electrical cable manufacturing method includes: in a joining device including a first facing surface and a second facing surface facing each other in a first direction, and a pressing member and a vibrating member facing each other in a second direction, setting an interval between the first facing surface and the second facing surface to a first distance; placing core wires between the first facing surface and the second facing surface having the interval set at the first distance; and joining the core wires by ultrasonic vibration. The core wires include core wires having different outer diameters. The first distance is larger than a maximum value between values of outer diameters of the core wires and smaller than the sum of the maximum value and a minimum value.