Ultrasonic Terminal-Wire Joining for Flexible Wire Orientation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for joining terminals and electric wires, such as those described in JP2015-135742 A, limit the orientation of the electric wire relative to the terminal, restricting the flexibility in assembling and requiring new terminals when the wire orientation changes.
Innovation Solution
A terminal-equipped electric wire is formed by ultrasonic joining of a terminal with a core wire exposed from an insulation sheath, where the terminal includes a joining portion with a square or round shape, allowing the electric wire to be joined at various orientations relative to the terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crimping method is used to join terminal and electric wire, then joining strength is improved, but assembly flexibility deteriorates due to limited wire orientation
Solution Approach 1:
The patent replaces the traditional crimping mechanical joining method with ultrasonic vibration-based joining. This substitution allows the wire to be joined to the terminal in various orientations (not limited to axial alignment), thereby improving assembly flexibility while maintaining joining strength through the ultrasonic welding process.
Solution Approach 2:
The patent changes the joining method from crimping to ultrasonic joining, which fundamentally alters the joining parameters and mechanism. This parameter change enables the wire to be joined at different angles and orientations to the terminal, resolving the contradiction between joining strength and assembly flexibility.
2Ease of manufacture
If crimping method is used with fixed wire orientation, then manufacturing process is simplified, but device complexity increases when orientation changes are needed
Solution Approach 1:
The ultrasonic joining method serves multiple functions: it maintains joining strength like crimping but also allows flexible wire orientation in various directions. This multi-functionality eliminates the need to prepare different terminal arrangements for different wire orientations, reducing device complexity while maintaining manufacturing simplicity.
3Ease of manufacture
If traditional joining method is used, then joining process is simple, but assembly freedom deteriorates due to orientation limitations
Solution Approach 1:
The patent substitutes crimping with ultrasonic joining, which simplifies the joining process while simultaneously improving assembly freedom. The ultrasonic vibration method requires no complex alignment or orientation constraints, allowing operators to assemble wires in various directions without complicating the joining process itself.
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 provides enhanced flexibility in assembling terminal-equipped electric wires, as the electric wire extending direction is not limited, allowing for easier adaptation to different connector designs and orientations.
Implementation Method 1
performing ultrasonic joining by ultrasonic vibration of the horn
Data Source
AI summary
A terminal-equipped electric wire is formed by joining a terminal and a core wire exposed from an insulation sheath of an electric wire by method of ultrasonic joining, and the terminal includes a joining portion having a square shape or a round shape in plan view, to which a distal end portion of the core wire is joined. When the joining portion has a square shape, a longitudinal direction of the electric wire is orthogonal to a longitudinal direction of the terminal.