Composite Metal Terminal for Electric Wire Connectors
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Solution Overview
Problem
Existing terminal-equipped electric wires require separate materials for terminals and conductor core wires, leading to inefficiencies in production and management, as stable electrical bonding between different metal types is difficult, necessitating the use of matching materials for both components.
Innovation Solution
A terminal-equipped electric wire with a composite metal terminal, where multiple metal materials are clad-bonded together, allowing a common terminal to be used with both copper and aluminum electric wires by exposing specific connection portions for electrical connection, preventing galvanic corrosion through offset positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different types of metal materials are used for terminals and conductor core wires, then conductivity and durability are improved, but stable electrical bonding becomes difficult
Solution Approach 1:
The terminal is constructed as a composite material consisting of a first metal material and a second metal material that are different from each other. This composite structure enables the terminal to be electrically bonded to conductor core wires made of different materials (copper or aluminum) while maintaining stable electrical connection and durability.
2Reliability
If matching materials are used for terminals and conductor core wires, then stable electrical bonding is achieved, but production efficiency decreases due to need for multiple terminal types
Solution Approach 1:
A single terminal type with composite metal structure serves multiple functions by being able to electrically bond with both copper conductor core wires and aluminum conductor core wires. This universal terminal design eliminates the need to prepare and manage multiple terminal types, thereby improving production efficiency while maintaining reliable electrical bonding.
3Reliability
If multiple terminal types are prepared for different wire types, then material matching is ensured, but management complexity and production overhead increase
Solution Approach 1:
The composite metal terminal structure enables one terminal type to replace multiple terminal types. The terminal includes a first connection portion for bonding to copper wires and a second connection portion for bonding to aluminum wires, achieving material compatibility without increasing terminal variety or management complexity.
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 solution enhances production efficiency by allowing a single terminal to be used for various wire types, preventing galvanic corrosion, and improving the reliability of electrical connections, even when exposed to water.
Implementation Method 1
a terminal formed of a composite metal material obtained by cladding a plurality of types of metal materials
Data Source
AI summary
A terminal-equipped electric wire, a connector including the terminal-equipped electric wire and a manufacturing method of the connector are provided. The terminal-equipped electric wire includes an electric wire including a conductor core wire formed of a conductor material and a terminal formed of a composite metal material in which a plurality of types of metal materials are clad-bonded with each other. The terminal includes a first connection portion and a second connection portion, each of which is formed of a metal material of respective one of the plurality of types of metal materials. The conductor core wire is electrically connected to one of the first and second connection portions, the one corresponding to the conductor material forming the conductor core wire.