Terminal-Equipped Wire with Cu-Sn Bonding for Vibration Resistance
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Solution Overview
Problem
The increasing number of electric components in automobiles requires a reduction in the size of terminal-equipped electric wire connectors while maintaining the strength of the connection between the conductor and the terminal, as existing methods struggle to ensure a secure connection, especially under vibration.
Innovation Solution
A terminal-equipped electric wire configuration featuring a conductor with a Cu—Sn alloy layer formed by continuous pinching using a terminal with a grip portion and a shell, where the grip portion is pressed by a pressing portion to create a strong alloy layer for enhanced connection strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional crimping methods are used to connect the conductor and terminal, then the connection can be established, but the holding force is insufficient under vibration and the connection strength deteriorates over time
Solution Approach 1:
The invention changes the physical-chemical state of the connection interface by forming a Cu-Sn alloy layer through diffusion bonding. This transforms the connection mechanism from purely mechanical interlocking to a combination of metallurgical bonding and mechanical constraint, significantly enhancing the holding force and resistance to vibration.
Solution Approach 2:
The invention creates a composite structure at the connection interface consisting of the Cu-Sn alloy layer formed between the conductor and terminal. This intermediate alloy layer acts as a bonding layer that combines the properties of both materials, providing superior adhesion and mechanical strength compared to direct metal-to-metal contact.
2Volume of moving object
If the connector size is reduced to accommodate increasing electric components, then space efficiency improves, but the connection strength between conductor and terminal becomes compromised
Solution Approach 1:
By changing the bonding mechanism from mechanical deformation alone to metallurgical bonding through Cu-Sn alloy formation, the invention achieves high connection strength in a more compact configuration. The alloy layer provides strong bonding without requiring excessive crimping force or larger terminal dimensions.
3Ease of manufacture
If mechanical crimping alone is used to join the conductor and terminal, then the manufacturing process is simple, but the connection reliability under vibration is insufficient
Solution Approach 1:
The invention utilizes thermal energy to activate diffusion bonding between the conductor and terminal, creating a Cu-Sn alloy layer. This thermal field application transforms the connection from purely mechanical to metallurgical, dramatically improving vibration resistance while adding only a heating step to the manufacturing process.
Solution Approach 2:
The invention employs thermal field (heating) to accelerate the diffusion process and alloy formation between Cu and Sn atoms at the interface. The elevated temperature increases atomic mobility and reaction rate, enabling rapid formation of the bonding alloy layer during the manufacturing 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 configuration significantly improves the holding force of the conductor to the terminal, providing a reliable connection that resists detachment even under vibration, with a holding force greater than conventional methods, and maintains the connection strength over time.
Implementation Method 1
the grip portion and the conductor are joined with an alloy layer, and the alloy layer contains a Cu—Sn alloy
Implementation Method 2
the grip portion pinches the conductor... the grip portion and the conductor are joined with an alloy layer
Implementation Method 3
the shell includes a pressing portion that presses at least a portion of the grip portion toward the conductor
Data Source
AI summary
A terminal-equipped electric wire includes an electric wire that includes a conductor, a terminal connected to the conductor, and a shell attached to the terminal. The terminal includes a grip portion that pinches the conductor. The shell includes a pressing portion that presses at least a portion of the grip portion toward the conductor. The grip portion and the conductor are joined with an alloy layer. The alloy layer contains a Cu—Sn alloy.