Fusion-Bonded Wire Terminal Geometry for Stronger Harness Connections
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Solution Overview
Problem
The bonding strength between the end portion of an electric wire and a terminal component in fusion-bonded terminal-attached electric wires is not consistently sufficient, lacking a clear understanding of the required bonding state.
Innovation Solution
A terminal-attached electric wire design with a conductor-exposed portion fusion-bonded to a conductive metal bonding portion, featuring a fused connection portion shaped to avoid passing through an arc-shaped area around the placement surface, ensuring a sufficient volume and bonding length for enhanced bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fusion bonding is used to connect the electric wire end portion to the terminal component, then bonding speed and automation are improved, but bonding strength consistency deteriorates due to unclear bonding state requirements
Solution Approach 1:
The patent applies parameter changes by precisely controlling the shape parameters of the fused connection portion. Specifically, it defines geometric constraints including: the contour line not passing through the arc-shaped area, the distance from the end surface to the contour line being 0.05-0.15 times the conductor outer diameter, and the included angle being 45-60 degrees. These parameter specifications ensure consistent bonding strength while maintaining fusion bonding efficiency.
Solution Approach 2:
The patent replaces mechanical crimping systems with fusion bonding (laser welding or resistance welding). This substitution improves productivity and automation while the defined geometric parameters of the fused connection portion ensure consistent bonding strength, resolving the contradiction between speed and reliability.
2Ease of manufacture
If the fused connection portion shape is not properly controlled, then manufacturing flexibility is improved, but bonding strength deteriorates
Solution Approach 1:
The patent establishes specific parameter ranges for the fused connection portion: distance from end surface to contour line (0.05-0.15×conductor diameter), included angle (45-60°), and the contour line position relative to the arc-shaped area. These parameters provide clear manufacturing guidelines that maintain both flexibility and bonding strength.
Solution Approach 2:
The patent defines minimum requirements for the fused connection portion geometry, such as the contour line must not pass through the arc-shaped area and the distance must be at least 0.05 times the conductor diameter. These partial specifications provide sufficient constraint to ensure bonding strength while allowing manufacturing flexibility within the defined ranges.
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 design achieves a robust bonding strength between the electric wire and terminal component, improving the connection reliability and durability.
Implementation Method 1
a fused connection portion in which the conductor-exposed portion and the bonding portion are at least partially melted and integrated to bond the conductor-exposed portion and the bonding portion to each other
Data Source
AI summary
A terminal-attached electric wire that can achieve sufficient bonding strength in the connection between the end portion of an electric wire and a terminal component, and provide a wire harness that includes such a terminal-attached electric wire. In a terminal-attached electric wire, a fused connection portion for bonding a conductor-exposed portion of an electric wire and a bonding portion of a terminal component to each other has such a shape that, in a cross section that passes through an extension center axis of the conductor-exposed portion and intersects with a placement surface of the bonding portion, a contour line of the fused connection portion does not pass through an inside of an arc-shaped area having a center at an end portion located near an edge on an electric wire extension side.