Grooved Connector Terminals for Airtight Resin Bonding
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Solution Overview
Problem
The existing connectors face issues with bondability and airtightness between metal terminals and resin housings, often resulting in fine gaps or cracks due to curing processes and temperature changes, and the surface processing techniques like laser irradiation can generate metal debris that acts as stress concentration points.
Innovation Solution
The connector design features grooves on the terminal surface, with an inclination angle between 100 and 150 degrees and a specific width ratio, which enhances bonding strength and airtightness by increasing the contact area and anchoring effect, and includes a debris removal step to prevent stress concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser irradiation is repeated multiple times to form grooves on the terminal surface, then bondability between metal and resin is improved, but metal debris is generated at the groove openings
Solution Approach 1:
The patent converts the harmful metal debris generated during laser groove formation into a beneficial sealing structure. By controlling the groove geometry (inclination surface angle of 100-150 degrees and width ratio of 0.58-1.0), the debris is pushed into the groove interior during molding, where it acts as a sealing filler rather than a harmful contaminant on the surface.
Solution Approach 2:
The patent applies different geometric properties to different regions of the groove. The inclination surface near the opening has a specific angle (100-150 degrees) to control debris placement, while the lower portion has a different width configuration (minimum width to maximum width ratio of 0.58-1.0) to ensure proper resin filling and anchoring. This localized geometric control resolves the debris problem while maintaining bonding strength.
2Strength
If the terminal surface is processed to have grooves, then bondability between metal and resin is improved, but fine gaps or cracks may form at the interface
Solution Approach 1:
The patent converts potential defect locations (groove openings) into sealing locations. The controlled groove geometry ensures that debris and resin work together to seal the groove openings, preventing fine gaps and cracks from forming at the interface between terminal and housing.
Solution Approach 2:
The groove structure is pre-designed with specific geometric parameters (inclination angle and width ratio) before molding. This preliminary structural preparation ensures that during the molding process, resin naturally fills the grooves and seals the interfaces, preventing gap formation without requiring additional sealing operations.
3Area of stationary object
If grooves are formed on the terminal surface, then contact area between metal and resin is increased, but device complexity increases
Solution Approach 1:
The patent replaces complex multi-step surface processing mechanisms with a simplified laser processing approach. The grooves are formed using laser irradiation with controlled parameters (inclination angle and width ratio), which automatically creates the desired geometry in a single or few passes, increasing contact area without proportionally increasing device complexity.
Solution Approach 2:
The patent optimizes specific geometric parameters of the grooves (inclination surface angle of 100-150 degrees and width ratio of 0.58-1.0) to achieve maximum bonding effectiveness with minimal structural complexity. By carefully controlling these parameters, the design increases contact area while maintaining a relatively simple groove structure that is easy to manufacture.
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 design achieves improved bondability and airtightness, with enhanced durability against temperature changes and reduced component count, eliminating the need for additional sealing components like O-rings.
Implementation Method 1
the surface of the terminal is subjected to processing to have grooves by repeating laser irradiation for a plurality of times and melting the terminal (metal)
Implementation Method 2
part of resin enters pores in a surface of a metal member and that bondability between metal and resin is improved due to an anchoring effect and an effect obtained by increasing a contact area
Data Source
AI summary
The connector includes a terminal and a resin housing that houses and retains the terminal. One or a plurality of grooves extend in a part of a region of a surface of the terminal. An inclination surface is formed near an opening of the groove. The groove is formed to have a part with a minimum width parallel to the surface of the terminal and a part with a maximum width parallel to the surface of the terminal. An angle formed by the inclination surface with respect to the surface of the terminal is between 100 degrees and 150 degrees. Moreover, a ratio of the minimum width of the groove with respect to the maximum width of the groove is equal to or greater than 0.58 and less than 1.0. The terminal is embedded and fixed in the resin forming the housing.