Wire Bundle Joined Assembly Fusion Welding

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Solution Overview

Problem

The existing methods for joining a wire bundle to a metallic member result in a reduction in productivity due to the need to loosen the conductive wires to remove inter-wire insulating layers, which complicates the production process.

Innovation Solution

A joined assembly and production method where the inter-wire insulating layers are removed using thermal energy generated by fusion-joining the head portion of the wire bundle to the metallic member, allowing the conductive wires to be fusion-joined without loosening the bundle, utilizing an energy beam to fuse and weld the head portion to the metallic member connecting portion and remove the insulating layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the wire bundle is loosened to remove inter-wire insulating layers, then the insulating layers can be removed for fusion-joining, but productivity is reduced due to the additional loosening step

Engineering Contradiction:

Improveease of insulating layer removalVSAvoidproduction efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The insulating layers are selectively removed only from the head portion of the wire bundle where fusion-joining is required, while the head extension retains its insulating layers. This selective extraction allows direct fusion-joining without loosening the entire bundle, maintaining productivity while enabling the joining process.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The insulating layers are removed in advance from the head portion before the fusion-joining process begins. This preliminary action prepares the joining surface so that when the wire bundle is positioned on the metallic member, the conductive wires are ready for immediate fusion-joining without requiring bundle loosening during the joining operation.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the wire bundle is kept tightly bound, then productivity is maintained, but the inter-wire insulating layers cannot be removed for fusion-joining

Engineering Contradiction:

Improveproduction efficiencyVSAvoidease of insulating layer removal

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The wire bundle has different structural characteristics in different regions: the head portion has removed insulating layers to enable fusion-joining, while the head extension maintains intact insulating layers to keep the bundle tightly bound. This local differentiation allows the bundle to remain bound for productivity while enabling joining where needed.

Inventive Principle:

Principle #3Local quality

3Productivity

If thermal energy is applied to remove insulating layers, then insulating layers can be removed without loosening, but the process requires precise thermal control

Engineering Contradiction:

Improveproduction efficiencyVSAvoidthermal energy control precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The thermal energy used for fusion-joining the conductive wires to the metallic member simultaneously serves to remove the insulating layers from the head portion. The heat that would otherwise be a byproduct or require separate application is converted into a useful function for insulating layer removal, achieving both tasks with a single process step.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 avoids the reduction in productivity by enabling the removal of inter-wire insulating layers and fusion-joining of conductive wires to the metallic member without loosening the wire bundle, ensuring stability and efficiency in the production process.

Implementation Method 1

The end-to-end joint is created by emitting an energy beam to fuse and weld the head portion of the wire bundle to the portion of the metallic member connecting portion

Methodology Applied

Scientific EffectFusion welding: Welding

Implementation Method 2

removal of the inter-wire insulating layers using thermal energy generated by fusion-joining the head portion of the wire bundle to the metallic member

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Data Source

PatentUS20240146139A1Joined assembly and production method thereof

Publication Date: 2024.05.02 DENSO CORP

AI summary

A joined assembly comprises a wire bundle and a metallic member joined to the wire bundle. The wire bundle includes a bundle of a plurality of conductive wires which are isolated from each other using inter-wire insulating layers and adhered to each other, the inter-wire insulating layers being made from insulating resin. The wire bundle includes a head portion and a head extension. The head portion is arranged on a first side of the wire bundle in a lengthwise direction (Da) thereof. The head extension extends from the head portion to a second side of the wire bundle away from the first side in the lengthwise direction. The metallic member includes a metallic member connecting portion arranged in contact with the head extension. The conductive wires are kept adhered to each other through the inter-wire insulating layers in the head extension and fusion-joined in the head portion to a portion of the metallic member connecting portion. The head portion of the wire bundle has the inter-wire insulating layers removed therefrom.