Electric Wire Terminal Ultrasonic Bonding and Crimping
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Solution Overview
Problem
Existing methods for manufacturing electric wires with terminals often result in cracking or peeling off of strands during the ultrasonic vibration process, leading to reduced electrical performance and variability.
Innovation Solution
A method involving ultrasonic bonding of strands on an exposed core wire, followed by crimping with a crimp terminal and simultaneous cutting of the bonded tip end, while the caulking pieces press the bonded part toward the bottom part, to reduce stress and prevent peeling or cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic vibration is applied to the core wire to weld strands, then electrical resistance between wire and terminal is reduced, but cracking and peeling off of strands may occur
Solution Approach 1:
The patent applies preliminary action by bonding the strands together with a bonding agent before applying ultrasonic vibration. This pre-bonding creates a more robust structure that can withstand the ultrasonic vibration process without cracking or peeling, while still achieving the desired reduction in electrical resistance between the wire and terminal.
2Shape
If the bonded part is cut after crimping, then the tip end can be trimmed, but stress concentration may cause peeling or cracking
Solution Approach 1:
The patent applies preliminary action by performing the cutting operation before the crimping process. The bonded part is trimmed to the desired length while the bonding agent is still fresh and providing structural support. After cutting, the crimping process is then applied to secure the wire to the terminal, preventing stress concentration that would otherwise cause peeling or cracking at the cut edges.
Solution Approach 2:
The patent inverts the conventional sequence of operations by cutting the bonded part before crimping rather than after. This reversal allows the cutting to be performed when the bonding agent provides maximum support, preventing stress concentration and subsequent peeling or cracking that would occur if cutting were done after crimping.
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 enhances the electrical performance of the electric wire with a terminal by minimizing strand peeling and cracking, ensuring consistent and improved electrical conductivity.
Implementation Method 1
a bonding process that forms a bonded part in which outer peripheral surfaces of a plurality of strands are bonded to one another... by applying ultrasonic vibration to the core wire from the jigs
Data Source
AI summary
A method for manufacturing an electric wire with a terminal includes forming a bonded part in which outer peripheral surfaces of strands are bonded to one another on an end portion of a core wire having the strands, in an electric wire in which the end portion is exposed from a covering; installing the bonded part onto a crimp terminal including a bottom part and a pair of caulking pieces extending from the bottom part and facing each other; crimping the caulking pieces to the bonded part, by sandwiching the crimp terminal and the electric wire between a first mold supporting the crimp terminal and a second mold moving relative to the first mold; and cutting a tip end portion projecting to outside from the caulking pieces in the bonded part by a cutting unit, while the caulking pieces are pressing the bonded part toward the bottom part.