Connection Terminal with Cutout for Resistance Welding Shape Control
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Solution Overview
Problem
Existing connection terminals face challenges in miniaturization, requiring additional processes for manufacturing and assembly, and struggle with forming insulating films on finer terminals, which complicates the connection process and increases the risk of short circuits.
Innovation Solution
A connection terminal design featuring a small-diameter conductive part and a large-diameter cylindrical part with a cutout part, allowing for electric welding without deforming the cylindrical shape, reducing the number of components and assembly complexity, and enabling the removal of linear materials without additional processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If connection terminals are miniaturized to meet finer pitch requirements, then the ability to test smaller features is improved, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The connection terminal employs a nested structure where a columnar part is inserted into a cylindrical part, and both are joined together. This nested design allows the terminal to achieve miniaturization while maintaining structural integrity and simplifying assembly, as the components fit together like nested dolls rather than requiring separate mounting operations.
Solution Approach 2:
The invention merges the cylindrical part and columnar part into a single integrated connection terminal through joining processes such as resistance welding or caulking. This merging reduces the number of discrete components and assembly steps, thereby decreasing manufacturing complexity while achieving the required miniaturization for finer pitch testing.
2Manufacturing precision
If additional processes are added to manufacture and assemble miniaturized terminals, then the manufacturing precision may be improved, but the productivity decreases
Solution Approach 1:
The cutout part is formed in advance on the cylindrical part before the joining process. This preliminary action allows the columnar part to be accurately positioned and joined to the cylindrical part in a single operation, thereby maintaining manufacturing precision while reducing the total number of sequential processes and improving overall productivity.
3Reliability
If insulating films are formed on finer terminals, then the reliability against short circuits is improved, but the manufacturing complexity increases
Solution Approach 1:
The insulating film is formed selectively on specific portions of the connection terminal rather than covering the entire surface. This local quality approach applies insulation only where needed to prevent short circuits, thereby maintaining reliability while reducing manufacturing complexity compared to full-surface coating processes.
4Strength
If the cylindrical part is deformed during welding, then the joining strength may be improved, but the shape maintenance and assembly ease worsen
Solution Approach 1:
The cutout part is formed on the cylindrical part before the welding or joining process. This preliminary action provides a relief feature that prevents deformation of the cylindrical shape during joining, thereby maintaining both the cylindrical shape and assembly ease while still achieving sufficient joining strength through the joining process.
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 design facilitates efficient manufacturing of fine connection terminals with reduced assembly complexity and prevents short circuits by maintaining the cylindrical shape during welding, ensuring reliable electrical connections.
Implementation Method 1
applying force from at least facing positions of an outer side of a cylindrical part toward an internal columnar part, and joining the cylindrical part and the columnar part like electric welding
Data Source
AI summary
Provided is a connection terminal that maintains an approximately circular shape before or after a cylindrical part is fixed by resistance welding. The connection terminal used for a connection jig interconnecting target points includes a small-diameter conductive part and a large-diameter cylindrical part disposed to surround the small-diameter conductive part. The small-diameter conductive part has a front end protruding from a front end of the large-diameter cylindrical part. A part of the small-diameter conductive part is joined to a part of the large-diameter cylindrical part. A cutout part is formed in a part of a strip portion around an axis of the cylindrical part that at least includes the portion of the large-diameter cylindrical part which is joined to the small-diameter conductive part.