Female Terminal Weld Structure for Ultrasonic Wire Joining
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Solution Overview
Problem
Existing female terminals with spring members welded to the base portion face damage during ultrasonic welding of electric wires due to localized loads from vibration, which can compromise the connection strength and reliability.
Innovation Solution
The female terminal features a base portion with side walls and a spring member having a laying plate and arm springs, where the laying plate and side walls are welded in an endless shape to distribute the ultrasonic welding vibration load, preventing damage and enhancing connection strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the base portion and spring member are welded in advance by laser welding to ensure favorable conductivity, then the electrical connection is improved, but the welded portion becomes vulnerable to damage during subsequent ultrasonic welding due to localized vibration loads
Solution Approach 1:
The patent divides the welded structure into multiple segments: the base portion, the spring member, and the laying plate. By segmenting the welding into multiple locations (base portion to electric wire connection portion, and laying plate to side walls), the vibration load during ultrasonic welding is distributed across multiple weld joints rather than concentrating on a single welded portion, thereby preventing damage while maintaining electrical conductivity.
Solution Approach 2:
The patent adds a spatial dimension to the welding structure by extending the laying plate along the side walls in addition to welding the base portion to the electric wire connection portion. This creates a three-dimensional welded structure where the vibration load is distributed across multiple spatial locations and planes, reducing the stress concentration on any single welded portion.
2Ease of manufacture
If the conductor of an electric wire is connected by ultrasonic welding to the electric wire connection portion, then the electrical connection is established, but the vibration during ultrasonic welding acts as a load on the previously welded portion between the base portion and spring member
Solution Approach 1:
The patent performs preliminary welding of the laying plate to the side walls before the ultrasonic welding of the conductor to the electric wire connection portion. This preliminary action creates an additional structural support that distributes the subsequent vibration load during ultrasonic welding, preventing excessive stress on the base portion-spring member welded portion while maintaining ease of manufacturing through sequential welding operations.
3Device complexity
If a simple linear welded portion is used between the base portion and spring member, then the manufacturing process is simplified, but the welded portion cannot effectively disperse the ultrasonic welding vibration load
Solution Approach 1:
The patent employs a laying plate that extends along the side walls in a curved or elongated configuration rather than a simple linear weld. This curved/elongated geometry increases the surface area and distribution of the welded portion, enabling it to effectively disperse the ultrasonic welding vibration load across multiple locations while maintaining a relatively simple manufacturing process through standard welding techniques.
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 endless welded portion effectively disperses the ultrasonic welding vibration load, preventing damage and ensuring reliable connections between the electric wire and the female terminal, even when the conductor is connected by ultrasonic welding to a previously welded base and spring member.
Implementation Method 1
it is conceivable to weld a base portion and a spring member by laser welding or the like to ensure favorable conductivity
Implementation Method 2
when a conductor of an electric wire is connected by ultrasonic welding to the electric wire connection portion of the female terminal
Data Source
AI summary
A female terminal, a female connector, a terminal-attached electric wire, a connector-attached electric wire, and a wire harness can prevent a welded portion from being damaged when a conductor of an electric wire is connected by ultrasonic welding to an electric wire connection portion of a female terminal with a base portion and a spring member welded together. A female terminal includes an electric wire connection portion with a conductor of an electric wire connected by ultrasonic welding, and a terminal connection portion with a male terminal connected. The terminal connection portion includes a base portion having a pair of side walls with a connection blade of a male terminal inserted therebetween, and a spring member attached to the base portion, the spring member includes a laying plate along the side walls and an arm spring, the side walls and the laying plate are welded at an endless welded portion.