Lead Terminal Pressing with Blasted Dies to Reduce Burrs
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Solution Overview
Problem
Existing manufacturing methods for lead terminals in electronic components, such as surface-mount type chip electrolytic capacitors, result in the generation of burrs due to plastic deformation and metal powder residue, which can lead to short-circuiting issues.
Innovation Solution
A manufacturing method involving the use of press dies with blasted surfaces to create random recesses and protrusions on the lead terminals, with a surface roughness of 1.0 to 3.5 μm, to reduce burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If press processing is applied to lead terminals to form plate shape, then the lead terminals can be assembled to seat plate, but burrs generate on the lead terminals causing short-circuiting risk
Solution Approach 1:
The press die surface is pre-treated with blasting to create recesses and protrusions before the pressing operation. This preliminary action modifies the die surface to control metal flow during pressing, preventing burr formation on the lead terminal while still achieving the required plate shape.
Solution Approach 2:
The press die surface is given non-uniform properties through blasting, creating localized recesses and protrusions. These local variations in the die surface quality control the plastic deformation of the lead terminal metal, directing flow into the recesses and preventing burr formation at critical areas.
2Object-generated harmful factors
If multiple groove-shaped recessed parts are provided on press dies to prevent metal powder residue, then metal powder can be contained, but burrs generate along the recessed parts
Solution Approach 1:
Instead of symmetric groove-shaped recesses, the invention uses asymmetric random patterns of recesses and protrusions created by blasting. This asymmetric, non-repetitive pattern prevents metal powder from concentrating in specific locations, thereby preventing burr formation along recessed parts while still containing metal powder residue.
Solution Approach 2:
The blasted press die surface creates a porous-like structure with numerous small recesses and protrusions. This porous surface structure effectively traps and contains metal powder particles during pressing, preventing them from forming burrs on the lead terminal surface.
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 method effectively reduces the generation of burrs on lead terminals, minimizing the risk of short-circuiting and improving the reliability of electronic components.
Implementation Method 1
the surface contacting the lead terminal, of at least one of the set of press dies, has been blasted to form recesses and protrusions randomly on the plate face of the lead terminal
Data Source
AI summary
A method for manufacturing an electronic component includes a pressing step in which each lead terminal extending from an electric element is placed between a set of press dies along its length direction and processed into a plate shape, wherein the surface contacting the lead terminal, of at least one of the set of press dies, has been blasted to form recesses and protrusions randomly on the plate face of the plate-shaped lead terminal.