Electroformed Connector Terminal with Pointed Portion

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Solution Overview

Problem

Conventional connector connection terminals face challenges in miniaturization and height reduction due to the limitations of press working processes, which require multiple operation steps and result in low productivity.

Innovation Solution

The development of a connector connection terminal formed through electroforming, featuring a fixed piece, a coupling portion, and a movable piece with pointed portions, allowing for the formation of a miniaturized and lowered-height terminal with fewer operation steps, and incorporating a cutout design to enhance reliability and prevent slip-out.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If press working is used to form the sharp pointed portion, then the terminal can be manufactured, but the number of operation steps increases and productivity decreases

Engineering Contradiction:

Improvemanufacturability of pointed portionVSAvoidproduction efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces the mechanical press working process with an electroforming process to form the pointed portion. The electroforming process uses electrical current to deposit metal and create the pointed shape in a single step, eliminating the need for multiple press operations and significantly improving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the manufacturing parameter from mechanical pressing to electrochemical deposition. By using electroforming, the pointed portion can be formed directly during the terminal manufacturing process without requiring subsequent mechanical operations, thus reducing the number of steps and increasing production efficiency.

Inventive Principle:

Principle #35Parameter changes

2Length of moving object

If the height and size of the sharp pointed portion are reduced for miniaturization, then the connector can be further miniaturized, but the manufacturing complexity increases with press working

Engineering Contradiction:

Improveheight of pointed portionVSAvoidmanufacturing process complexity

Core Design Contradiction:

Length of moving objectVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical pressing operations with a simpler electroforming process. The electroforming method can create precise, miniaturized pointed portions with controlled dimensions directly during terminal fabrication, avoiding the complexity of multiple press operations and tooling requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent forms the pointed portion during the initial electroforming manufacturing process rather than as a subsequent operation. This preliminary formation of the pointed structure integrates the feature creation into the base manufacturing step, reducing overall process complexity and enabling miniaturization.

Inventive Principle:

Principle #10Preliminary action

3Length of moving object

If the connector connection terminal is miniaturized and lowered in height, then the connector can be further reduced in size, but the contact reliability may be compromised

Engineering Contradiction:

Improveheight of terminalVSAvoidcontact reliability

Core Design Contradiction:

Length of moving objectVSReliability

Solution Approach 1:

The patent applies local quality by creating a concentrated pointed portion at the contact area. The electroforming process allows precise control of the pointed structure's geometry, ensuring adequate contact pressure and reliability even in miniaturized terminals. The pointed shape concentrates force locally to maintain reliable electrical contact despite reduced overall terminal size.

Inventive Principle:

Principle #3Local quality

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 the production of a miniaturized connector connection terminal with high productivity, reduced height, and improved contact reliability, while allowing for dense arrangement of connection pads without requiring high positioning accuracy, thus facilitating efficient assembly and preventing short circuits.

Implementation Method 1

the connector connection terminal is formed through electroforming

Methodology Applied

Scientific EffectElectroforming: Electrodeposition

Data Source

PatentUS7896675B2Connector connection terminal comprising a pointed portion formed through Electroforming and connector incorporating the same

Publication Date: 2011.03.01 OMRON CORP

AI summary

A connector connection terminal has a fixed piece to be inserted to a base of a connector, a coupling portion extending from the fixed piece, and a movable piece extending in parallel to the fixed piece to both sides from a free end of the coupling portion and being operated by an operation lever rotatably assembled to the base. At least one of the fixed piece and the movable piece includes at least one pointed portion. The connector connection terminal is formed through electroforming.