Connector Terminal Grooves Enhance Bonding Strength
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Solution Overview
Problem
Conventional high-voltage connectors have a large number of components, leading to high costs, complex assembly, and difficulties in achieving satisfactory bonding and airtightness, particularly with syndiotactic polystyrene (SPS) housings which exhibit poor adhesiveness and acrylic rubber sealing components that can split during assembly.
Innovation Solution
A connector design featuring grooves with protrusions on the terminal surface, embedded within a resin housing, which increases the contact surface area and anchoring effect, enhancing bonding strength and airtightness without the need for additional components like O-rings, and utilizing SPS for its heat and oil resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connectors use multiple components (O-rings, holders, rubber plugs) to ensure sealing and insulation, then airtightness and insulation are improved, but device complexity and assembly cost increase
Solution Approach 1:
The patent merges multiple separate sealing components (O-rings, holders, rubber plugs) into an integrated resin housing structure. The housing itself forms the sealing barrier through its molded geometry, eliminating the need for separate sealing elements while maintaining airtightness and insulation functions.
Solution Approach 2:
The resin housing serves multiple functions simultaneously: it provides structural support, electrical insulation, environmental sealing, and mechanical protection. This multi-functional design replaces the need for multiple specialized components, reducing overall device complexity while maintaining reliability.
2Temperature
If SPS material is used for housing to achieve heat and oil resistance, then temperature and chemical resistance are improved, but adhesiveness deteriorates
Solution Approach 1:
The patent applies local quality modification by adding protrusions at specific locations on the terminal surface where bonding is required. These protrusions create localized anchoring points that enhance adhesiveness only where needed, while the bulk SPS material maintains its heat and oil resistance properties.
Solution Approach 2:
The protrusions are pre-formed on the terminal surface before assembly, creating ready-made anchoring structures that facilitate bonding. This preliminary preparation of the surface geometry enables improved adhesiveness without requiring post-assembly modifications or additional bonding steps.
3Reliability
If conventional connectors use multiple separate components, then sealing and insulation functions are achieved, but manufacturing cost and assembly time increase
Solution Approach 1:
The patent combines multiple separate sealing and insulation components into a single integrated resin housing. This reduces the number of assembly steps and components to be handled, directly decreasing assembly time while maintaining sealing functionality through the housing's molded 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 connector achieves excellent bonding and airtightness with reduced component count, improved peel strength, and enhanced airtightness under increased pressure, shortening waterproofing treatment time and applicable in various electronic and automotive applications.
Implementation Method 1
one groove or a plurality of grooves, each of which includes a directional component perpendicular to the lengthwise direction of the electric wire and has protrusions on a surface thereof, extends across a region of a portion of the surface of the terminal, and the terminal is embedded and secured within the resin that constitutes the housing in this portion containing the region across which the groove extends
Data Source
AI summary
A connector comprising a terminal that is connected to an electric wire, and a resin housing that houses and holds the terminal, wherein one groove or a plurality of grooves, each of which includes a directional component perpendicular to the lengthwise direction of the electric wire and has protrusions on the surface thereof, extends across a region of a portion of the surface of the terminal, and the terminal is embedded and secured within the resin that constitutes the housing in this portion including the region across which the groove extends. By employing this type of structure, the number of components can be reduced, and excellent bonding and airtightness is achieved between the terminal and the housing.