Electric Wire Terminal Mold Uniform Heat Distribution
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Solution Overview
Problem
Existing mold technologies face issues with adhering molten aluminum conductor wires to copper alloy electrodes, leading to removal difficulties and uneven Joule heat generation, resulting in shrinkage defects and poor molding quality of electric wire terminals.
Innovation Solution
A mold design featuring a first electrode with a looped conductor, a hole forming jig, a wire holding jig, and a second electrode with a conductor pressing protrusion, where the electrodes have contacting and pressing surfaces conforming to the looped conductor's overlap portion, allowing for uniform heat distribution and easy removal of the molded terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the wire pressing protrusion has flat surfaces that are flush with each other, then the structure is simple, but the Joule heat generation becomes non-uniform causing shrinkage defects
Solution Approach 1:
The pressing surfaces of the wire pressing protrusion are designed with different shapes (circular arc surfaces) instead of uniform flat surfaces. This local variation in surface geometry creates different contact areas with the conductor wires at different positions, resulting in uniform Joule heat generation across the overlap portion while maintaining relatively simple overall structure.
2Reliability
If the conductor wires are made of aluminum or aluminum alloy, then the electrical conductivity is high, but the molten conductor adheres to the copper alloy electrode making removal difficult
Solution Approach 1:
A release agent is introduced as an intermediary substance between the aluminum conductor wires and the copper alloy electrode. This release agent prevents direct adhesion between the molten aluminum and copper surfaces, allowing the molded terminal to be easily removed after forming while maintaining the high electrical conductivity of the aluminum conductor.
3Stability of the object's composition
If the looped conductor is placed with distal end and base part overlapping, then the closed loop form is achieved, but the overlap portion melts faster causing uneven melting
Solution Approach 1:
The wire pressing protrusion features pressing surfaces with different shapes (circular arc surfaces) that create varying contact areas at different positions of the overlap portion. This local variation compensates for the naturally higher heat generation at the center, achieving uniform melting across the entire overlap region while maintaining the closed loop structure.
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 mold ensures uniform Joule heat generation and prevents adherence issues, resulting in high-strength, defect-free ring terminal formation with improved molding quality and ease of removal.
Implementation Method 1
the molten conductor easily adheres to the wire accommodating groove 511 of the female pressing electrode 503 made of copper alloy for example
Implementation Method 2
a second electrode having a conductor pressing protrusion configured to be fitted in a conductor molding groove defined by the first electrode and the wire holding jig to press and heat the looped conductor between the first electrode and the second electrode
Data Source
AI summary
A mold includes a first electrode on which a looped conductor of an electric wire is placed, the looped conductor being an exposed conductor of the electric wire from which a coating is removed and having an overlap portion at which different parts of the exposed conductor overlap each other, a hole forming jig provided upright on the first electrode to extend through an inner hole of the looped conductor, a wire holding jig arranged to surround the first electrode, and a second electrode having a conductor pressing protrusion configured to be fitted in a conductor molding groove defined by the first electrode and the wire holding jig to press and heat the looped conductor. The wire holding jig has a plurality of separable holding jigs configured to hold the looped conductor between the separable holding jigs from a direction perpendicular to an axis of the hole forming jig.