Terminalized Wire Die with Conductor Accommodation Parts
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Solution Overview
Problem
Existing terminalized electric wire molding processes often result in insufficiently molded annular terminal parts due to clearance issues, leading to strength deficiencies and uneven contact surfaces, as the molten conductor does not adequately spread, causing burrs or projections and insufficient thickness.
Innovation Solution
A die system comprising a first electrode, a hole forming jig, an electric wire pressing jig, and a second electrode, where the annular conductor is mounted with its end side superposed on the root side, and a clearance intruding bulge part is used to prevent the molten conductor from entering clearance areas, ensuring even distribution and solidification within the die's cavity, thereby forming a robust and evenly contacted annular terminal part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the end side of the core element wires is superposed on the root side to eliminate clearance, then the molten conductor can spread adequately without shrinkage cavities, but the cross-sectional area increases causing the molten conductor to be pushed out and form burrs or projections
Solution Approach 1:
The patent applies local quality by creating a conductor accommodation part with a specific recessed shape at the location where the superposed configuration part is held. This localized structural modification allows the molten conductor to flow into the recessed space rather than being pushed out to form burrs, while maintaining the superposed configuration's benefit of adequate conductor spread.
Solution Approach 2:
The conductor accommodation part is pre-formed in the die structure before the molding process. This preliminary preparation of the recessed space ensures that when the conductor is superposed and molten, there is already an appropriate space for the excess material to flow into, preventing defect formation during the actual molding operation.
2Ease of operation
If a clearance is formed between the superposed configuration part and the guide pin, then the guide pin can be inserted, but the molten conductor enters the clearance causing insufficient strength or uneven contact surfaces
Solution Approach 1:
The conductor accommodation part provides a localized recessed space specifically positioned to receive molten conductor that might otherwise enter the clearance area. This localized structural feature prevents the harmful effect of molten conductor entering the clearance while maintaining the clearance's functionality for guide pin insertion.
Solution Approach 2:
The patent converts the potentially harmful clearance space into a beneficial feature by providing the conductor accommodation part that guides the molten conductor into a controlled recessed area. The clearance that would normally cause defects is now part of a controlled flow path that leads to proper conductor distribution and strength enhancement.
3Manufacturing precision
If the cross-sectional area of the superposed configuration part is increased, then clearance elimination is achieved, but the molten conductor is pushed out from the die matching part
Solution Approach 1:
The conductor accommodation part creates a localized recessed space that accommodates the increased volume of molten conductor resulting from the superposed configuration. This local structural modification allows the system to maintain the benefits of clearance elimination while providing an appropriate receptacle for the additional conductor material.
Solution Approach 2:
The patent addresses the volume increase by utilizing a spatial dimension - creating a recessed space with depth in the vertical direction. This dimensional approach allows the molten conductor to be accommodated in three-dimensional space rather than being constrained to a two-dimensional plane, preventing material pushout while maintaining clearance elimination.
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 die effectively pressurizes and heats the annular conductor to form a finely terminalized part with enhanced strength and even contact surfaces, preventing burrs and projections, and ensuring a consistent thickness, thus improving the molding quality of terminalized electric wires.
Implementation Method 1
the second electrode has a conductor-pressing protrusion which is fitted to a conductor-forming recessed part defined and formed by the first electrode and the electric wire pressing jig so as to pressurize and heat the annular conductor between the first electrode and the second electrode
Implementation Method 2
pressurize and heat the annular conductor between the first electrode and the second electrode
Data Source
AI summary
A die for a terminalized electric wire is provided with a first electrode, a hole forming jig, an electric wire pressing jig which surrounds a periphery of the first electrode, a second electrode and conductor accommodation parts. The conductor accommodation parts are recessed in molded inner wall surfaces at both sides of the electric wire pressing jig which holds a superposed configuration part in which the end side is superposed on the root side of the annular conductor in the vertical direction. A part of a molten conductor of the superposed configuration part flows into the conductor accommodation parts.