Ultrasonic Core Wire Bundle Terminal Connection
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Solution Overview
Problem
The existing connection structure between a terminal and an electric wire faces challenges in ensuring sufficient conduction and operability as the number of core wires increases, leading to insufficient pressure for efficient electrical performance.
Innovation Solution
A connection structure that involves forming a core wire bundle by ultrasonically joining exposed core wires and then press-fastening it into a bottomed tubular terminal connection part, with serrated surfaces for enhanced contact and reduced resistance, allowing for improved electrical performance and operability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of core wires is increased to accommodate larger electric wire sizes, then the current carrying capacity is improved, but the conduction between core wires becomes insufficient due to inadequate pressure
Solution Approach 1:
The core wires are twisted together to form a bundled structure before insertion into the terminal. This preliminary action ensures that the core wires are pre-positioned and pre-compressed, enabling sufficient conduction pressure to be achieved even with a large number of core wires, thereby resolving the contradiction between increased wire quantity and maintained conduction reliability
Solution Approach 2:
The terminal structure is designed with specific dimensional parameters including a reception space depth of 0.5-1.5 times the bundle diameter and a press-fastening portion depth of 0.3-0.8 times the bundle diameter. These parameter changes optimize the compression force distribution, ensuring reliable conduction across multiple core wires by controlling the pressure applied to the bundled core wires
2Device complexity
If multiple core wires are inserted individually into the terminal, then the connection structure is simple, but the operability and insertion ease deteriorate
Solution Approach 1:
Multiple individual core wires are merged into a single bundled structure through twisting before insertion. This merging approach maintains the simplicity of the terminal structure while dramatically improving operability, as the bundled core wires can be inserted as one unit rather than requiring individual insertion of multiple wires, thus resolving the contradiction between structural simplicity and insertion ease
3Area of stationary object
If core wires are pressed individually against the terminal wall, then the contact area is maximized, but the connection strength and electrical performance become insufficient
Solution Approach 1:
The core wires are pre-twisted into a compact bundle with controlled dimensions before insertion. This preliminary action ensures that when the bundle is press-fastened in the terminal, the compression force is distributed effectively across all core wires, achieving both sufficient contact area and strong mechanical connection, thereby resolving the contradiction between contact area and connection strength
Solution Approach 2:
The terminal is designed with optimized depth parameters for the reception space and press-fastening portion, creating controlled compression zones. These parameter changes ensure that the bundled core wires receive adequate compressive force to achieve strong mechanical bonding and low electrical resistance, resolving the contradiction between contact area and connection strength
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 enhances electrical performance by ensuring effective conduction and reducing connection resistance, while improving the ease of inserting the electric wire into the terminal.
Implementation Method 1
forming a core wire bundle by ultrasonically joining exposed core wires
Data Source
AI summary
A connection structure between a terminal and an electric wire includes: a terminal with a tubular shape continuously having an electric wire connection part with a bottomed tubular shape and an electrical contact part; and an electric wire having a plurality of core wires and an insulating sheath for coating the plurality of core wires, the plurality of core wires being exposed from the insulating sheath by peeling off the insulating sheath at an end part, and the plurality of core wires being inserted into the electric wire connection part and being press-fastened. The plurality of core wires exposed at the end part of the electric wire) are integrally joined to form a core wire bundle, and the core wire bundle is inserted into the electric wire connection part and is press-fastened.