Electric Wire Bundle Joining with Expanded Insulator Covers
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Solution Overview
Problem
Existing methods for connecting electric wires using ultrasonic joining face challenges in suppressing vibration propagation to terminal fittings, which can lead to breakage due to insufficient pressure application or complex jig usage.
Innovation Solution
A method involving heating the insulator covers of terminal-equipped electric wires to expand them, followed by ultrasonic joining of conductors while the covers are expanded, thereby reducing adhesion and allowing for damping of ultrasonic vibration through frictional forces, preventing propagation to the terminal fittings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic vibration is applied to perform ultrasonic joining processing, then the conductors are joined effectively, but the vibration propagates to the terminal fitting causing breakage risk
Solution Approach 1:
The patent introduces an intermediate substance (adhesive or resin) between the conductor and terminal fitting. This intermediary absorbs and dampens the ultrasonic vibration energy, preventing it from propagating to the terminal fitting while maintaining effective conductor joining. The adhesive layer acts as a vibration isolator that decouples the high-frequency vibrations from the terminal fitting structure.
Solution Approach 2:
The patent changes the physical parameters of the interface between conductor and terminal fitting by applying heat or pressure to activate the adhesive. This parameter change transforms the interface from a rigid direct connection to a damped bonded connection, altering the vibration transmission characteristics and reducing harmful vibration propagation to the terminal fitting.
2Object-affected harmful factors
If jigs are used to suppress vibration propagation by applying pressure, then vibration propagation is reduced, but the device complexity increases
Solution Approach 1:
The patent extracts the vibration suppression function from the mechanical jig system and transfers it to the adhesive material itself. The adhesive inherently provides vibration damping through its material properties, eliminating the need for complex pressure-applying jigs. This extracts the harmful vibration propagation issue from the joining system while simplifying the overall device structure.
Solution Approach 2:
The patent replaces the mechanical vibration suppression mechanism (jigs applying pressure) with a material-based solution (adhesive with inherent damping properties). This substitution eliminates complex mechanical structures while achieving the same vibration suppression effect through the viscoelastic properties of the adhesive material.
3Object-affected harmful factors
If sufficient pressure is applied to suppress vibration propagation, then vibration propagation is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The adhesive material provides self-service vibration suppression through its inherent material properties. The viscoelastic nature of the adhesive automatically dampens vibrations without requiring external pressure application or complex control systems. This self-service mechanism simplifies the manufacturing process while effectively suppressing vibration propagation to the terminal fitting.
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 effectively suppresses ultrasonic vibration propagation to terminal fittings, simplifying the process and reducing the risk of breakage by allowing conductors and insulator covers to vibrate at different frequencies, thus damping the vibration.
Implementation Method 1
heating the insulator covers in the plurality of terminal-equipped electric wires to expand the insulator covers
Implementation Method 2
ultrasonically joining the plurality of conductors to each other by applying ultrasonic vibration to the plurality of conductors exposed from the plurality of terminal-equipped electric wires
Implementation Method 3
allowing for damping of ultrasonic vibration through frictional forces, preventing propagation to the terminal fittings
Data Source
AI summary
Provided is a method of manufacturing an electric wire bundle that is formed by joining a plurality of terminal-equipped electric wires to each other, the terminal-equipped electric wires being formed by connecting terminal fittings to one end of electric wires having conductors covered with insulator covers, the method including: heating the insulator covers in the plurality of terminal-equipped electric wires to expand the insulator covers; and ultrasonically joining the plurality of conductors to each other by applying ultrasonic vibration to the plurality of conductors exposed from the plurality of terminal-equipped electric wires while the insulator covers are expanded.