Connector Terminal Stamping and Plating Separation
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Solution Overview
Problem
The existing method for manufacturing connector terminals, where gold plating is applied to the electric contact part and tin plating to the electric wire crimping part, often results in overlapping plating ranges, leading to potential corrosion and reduced contact performance, necessitating costly partial masking and increased production costs.
Innovation Solution
A method where the connector terminal is stamped with the electric wire crimping part extended perpendicular to the feeding direction and the electric contact part parallel to it, allowing for separate gold and tin plating applications without overlapping, thereby eliminating the need for masking and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the electric contact part is bent perpendicular to the bottom plate to achieve proper connector terminal shape, then the connector terminal can be properly attached to housing, but the electric contact part does not exist on the same plane as the chain part causing bending angle changes and improper reel winding
Solution Approach 1:
The patent applies dimensionality change by arranging the electric contact part in the feeding direction (parallel to chain movement) rather than perpendicular to it. This allows the electric contact part to remain on the same plane as the chain part, enabling proper reel winding while maintaining the L-shaped configuration when the terminal is installed. The electric contact part is oriented along the feeding direction and then bent 90 degrees during installation, achieving both reel compatibility and proper terminal shape.
2Reliability
If gold plating and tin plating are applied to respective parts with limited material width, then proper plating coverage is achieved, but the plating ranges overlap causing tin plating to adhere to gold plated area and reduce contact performance
Solution Approach 1:
The patent applies preliminary action by performing the stamping operation before plating, with the electric contact part extended in the feeding direction. This preliminary arrangement of the stamped terminal piece ensures that subsequent gold plating on the electric contact part and tin plating on the electric wire crimping part do not overlap, preventing corrosion and maintaining contact performance without requiring masking operations.
Solution Approach 2:
The patent applies local quality by extending the electric contact part in the feeding direction during stamping, creating distinct spatial zones for gold plating and tin plating. This local geometric modification ensures that the gold-plated electric contact part and tin-plated electric wire crimping part occupy separate regions along the feeding direction, eliminating plating overlap and the associated corrosion risk.
3Reliability
If partial plating by masking is performed to prevent plating overlap, then contact performance is maintained, but production cost increases
Solution Approach 1:
The patent eliminates masking operations by performing stamping with the electric contact part extended in the feeding direction before plating. This preliminary geometric arrangement ensures automatic separation of gold plating and tin plating zones, removing the need for costly masking steps while maintaining contact performance and reducing production costs.
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 approach enables effective application of gold plating to the electric contact part and tin plating to the electric wire crimping part without masking, resulting in improved contact performance and reduced production costs.
Implementation Method 1
a stamping step of stamping from an electrically conductive metal plate a stamped terminal piece formed as the connector terminal
Implementation Method 2
a gold plating step of applying a gold plating to the electric contact part
Implementation Method 3
a tin plating step of applying a tin plating to the electric wire crimping part
Implementation Method 4
a bending step of forming the connector terminal by a bending work
Data Source
AI summary
In a stamping step, when a stamping terminal piece formed as a connector terminal is stamped, an electric wire crimping part is stamped and extended from a chain part in a direction perpendicular to a feeding direction, an electric contact part is stamped and extended from the electric wire crimping part in a direction parallel to the feeding direction and a range to which a gold plating is applied by a gold plating step is not overlapped on a range to which a tin plating is applied by a tin plating step in the feeding direction.