Connector Terminal Plating for Sealing Surface Smoothness
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Solution Overview
Problem
Conventional relay connectors experience a decrease in close contact between the connector terminal and the sealing member due to fine irregularities generated on the fracture surface during the punching process, leading to potential liquid leakage.
Innovation Solution
A method involving the punching of a metal plate to form an intermediate material, followed by plating and a cleaning process, which includes forming a connector terminal with a smooth fracture surface by ensuring the non-plated portions do not contact the sealing member, thereby improving the close contact between the terminal and the sealing member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the metal plate is punched by means of press working to form the connector terminal, then the connector terminal can be manufactured efficiently, but fine irregularity is generated on the fracture surface which decreases close contact with the sealing member
Solution Approach 1:
The patent applies a plating process to the intermediate material before final assembly. This preliminary plating action fills the fine irregularities on the fracture surface created by punching, ensuring a smooth surface for the sealing member contact before the terminal is installed in the connector housing.
Solution Approach 2:
The patent converts the harmful effect of fine irregularities on the fracture surface into a benefit by applying plating that fills these irregularities. The plating material transforms the rough surface into a smooth one, improving close contact with the sealing member while maintaining the efficient punched manufacturing process.
2Ease of manufacture
If press working oil is sprayed on the metal plate during punching, then the punching process can be performed smoothly, but the press working oil remains on the intermediate material causing potential contamination
Solution Approach 1:
The patent implements a continuous manufacturing process where punching, plating, and assembly occur in sequence without interruption. The plating process immediately follows punching while the intermediate material is still in production, ensuring press working oil is covered and preventing contamination before assembly.
Solution Approach 2:
The plating layer acts as an intermediary substance that covers the press working oil remaining on the intermediate material after punching. This plating layer prevents the oil from causing contamination or affecting the quality of the final connector assembly.
3Manufacturing precision
If the intermediate material is plated to smooth the fracture surface, then close contact with the sealing member is improved, but the plating adds an additional manufacturing step
Solution Approach 1:
The patent combines the plating process with the existing punching and assembly operations into an integrated manufacturing flow. The plating is applied to intermediate materials in batches between punching and assembly, merging multiple functions into a coordinated process sequence that minimizes overall complexity.
Solution Approach 2:
The patent changes the surface parameters of the intermediate material by applying plating, transforming the rough fracture surface into a smooth surface suitable for sealing contact. This parameter change is achieved through controlled plating processes that modify surface characteristics without fundamentally changing the manufacturing approach.
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 method enhances the close contact between the connector terminal and the sealing member by smoothing the fracture surface and preventing foreign matter attachment, effectively preventing liquid leakage.
Implementation Method 1
a second process of plating the intermediate material
Implementation Method 2
punching the metal plate by means of press working while spraying the metal plate with press working oil
Data Source
AI summary
An object of the present invention is to provide a method for manufacturing a connector terminal received in a terminal-receiving chamber, passing through a sealing member, and brought into close contact with the sealing member, and a connector, which are the method for manufacturing a connector terminal, and the connector, for improvement in close contact between the sealing member and the connector terminal. Provided is a method for manufacturing a connector terminal received in a terminal-receiving chamber of a housing, passing through a sealing member filled in the terminal-receiving chamber, and brought into close contact with the sealing member, and the method includes a first process of punching a non-plated metal plate to form an intermediate material and a second process of covering the intermediate material with plating.