Fork Terminal Wire Connection Without Soldering Heat Damage
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Solution Overview
Problem
Existing conductive yarn wires used in fabric products are not resistant to high temperatures, necessitating a new connection method for electrical signal transmission that is quick, environmentally-friendly, and suitable for mass production.
Innovation Solution
A quick connection structure and method using a fork-shaped terminal with an accommodation space and interference fit to connect and fix a conductive wire to a connection terminal without solder, utilizing friction force for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect conductive wire to connection terminal, then reliable electrical connection is achieved, but high temperature damage occurs to heat-sensitive materials
Solution Approach 1:
The patent replaces the thermal field (soldering) with a mechanical field (interference fit). The fork-shaped terminal uses elastic deformation to create a mechanical interference fit with the connection terminal, achieving reliable electrical connection without high temperature. The elastic material deforms during insertion and maintains continuous contact pressure, ensuring stable electrical connection while avoiding thermal damage to heat-sensitive materials.
2Reliability
If traditional connection methods are used, then secure connection is achieved, but connection time is long and mass production efficiency is low
Solution Approach 1:
The connection structure is segmented into distinct functional parts: the conductive wire, the fork-shaped terminal with accommodation space, and the connection terminal with mounting hole. This segmentation allows each component to be optimized independently and assembled quickly through a simple insert-and-press operation, significantly improving mass production efficiency while maintaining secure connection through the interference fit mechanism.
Solution Approach 2:
The fork-shaped terminal is pre-formed with an accommodation space that guides the conductive wire into position before the final pressing operation. This preliminary positioning action ensures proper alignment and reduces the complexity of the connection process, enabling faster assembly in mass production while maintaining connection security.
3Reliability
If soldering process is used, then electrical connection is achieved, but environmental pollution and complex process are introduced
Solution Approach 1:
The patent eliminates the soldering process entirely by using a mechanical interference fit system. The elastic fork-shaped terminal deforms during insertion into the connection terminal and maintains continuous contact pressure, ensuring stable electrical connection without any soldering materials or complex thermal processes, thereby simplifying the manufacturing process and reducing environmental pollution.
4Productivity
If interference fit is used to connect fork-shaped terminal to mounting hole, then quick connection is achieved, but connection strength must be sufficient
Solution Approach 1:
The patent optimizes the interference fit by carefully controlling geometric parameters: the diameter of the mounting hole, the dimensions of the fork-shaped terminal, and the elastic properties of the material. These parameter changes ensure that the interference fit provides sufficient connection strength while maintaining quick assembly. The elastic material's deformation characteristics are specifically selected to achieve the right balance between insertion ease and connection strength.
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
Enables quick, simple, and secure connection of conductive wires to connection terminals, suitable for materials that cannot withstand high temperatures, facilitating mass production and environmental sustainability.
Implementation Method 1
the fork portion of the fork-shaped terminal and the conductive wire are pressed into the mounting hole of the connection terminal, and the fork portion of the terminal and the mounting hole of the connection terminal form an interference fit
Data Source
AI summary
Quick connection structure and method for a conductive wire and a connection terminal are provided. The quick connection structure includes at least one conductive wire, at least one fork-shaped terminal, and the connection terminal. One end of the fork-shaped terminal has a fork portion. The connection terminal is disposed on a connector body or a flexible board body and has a terminal body, and at least one mounting hole is formed on the terminal body. During assembly, the conductive wire is inserted into channels of jigs to allow the conductive wire arranged horizontally to be arranged vertically. The fork-shaped terminal is pressed into the jig to cover the conductive wire. The conductive wire and the fork-shaped terminal are pressed into the mounting hole of the connection terminal. A material tape of a row of the fork-shaped terminal is removed along a break line of the fork-shaped terminal.