Lead Wire Connection Structure for Vibration-Stable Metal Plate Contact
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Solution Overview
Problem
Existing lead wire connection structures to metal plates face issues with reliable and stable connections due to the restoring force of the core wire and insulative coating, leading to unstable contact and potential disconnection from vibrations or impacts.
Innovation Solution
A lead wire connection structure featuring a metal plate with protrusions that sandwich and hold the lead wire in place, ensuring accurate positioning and minimizing movement, thereby maintaining a stable electrical connection through a connection space between the protrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the lead wire is bent in a U-shape and held at a fixed position away from the tip end, then the middle of the lead wire can be positioned stably, but the restoring force of the core wire causes the tip end to separate from the metal plate surface, preventing reliable connection
Solution Approach 1:
The holding protrusions are divided into multiple segments (first holding protrusion and second holding protrusion) that independently sandwich different portions of the lead wire. This segmentation allows the lead wire to be held at multiple points, preventing the tip end from separating while maintaining stability at the middle portion.
Solution Approach 2:
The holding protrusions extend in the width direction of the lead wire, creating a multi-dimensional constraint system. By sandwiching the lead wire from both sides in the width direction, the structure prevents displacement in multiple directions, ensuring the tip end remains in contact with the metal plate surface while the middle portion maintains stable positioning.
2Stability of the object's composition
If the lead wire is held at a position away from the tip end, then the middle portion can be secured, but the tip end of the core wire easily moves and cannot be disposed in a non-moving state
Solution Approach 1:
The holding protrusions are pre-formed on the metal plate before lead wire installation. These protrusions are positioned to sandwich the lead wire at specific locations, preliminarily establishing the correct positioning geometry. When the lead wire is inserted, it is automatically guided and held in the precise required position, ensuring both middle stability and tip end precision without requiring additional adjustment steps.
3Reliability
If the tip end of the lead wire is soldered or welded to the metal plate, then electrical connection can be established, but the connection structure becomes complex requiring additional components like solderless terminals
Solution Approach 1:
The holding protrusions and the metal plate are merged into a single integrated structure. The holding protrusions are formed directly on the metal plate, eliminating the need for separate holding components or additional assembly steps. This merging maintains reliable electrical connection through direct contact between the lead wire tip end and metal plate while simplifying the overall connection structure.
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 configuration ensures a reliable and stable electrical connection by maintaining the lead wire's connection portion close to the metal plate, preventing disconnection from vibrations or impacts, and allowing for long-term stable contact.
Implementation Method 1
a pair of holding protrusions that protrude from a front surface of the metal plate, and sandwich at least two parts of the lead wire to dispose the lead wire in a fixed position
Data Source
AI summary
A connection portion of a lead wire is close to a surface of a metal plate, held at an accurate position, and held while preventing the wire from being movable. A connection structure of the lead wire includes the metal plate, the lead wire connected to the surface of the metal plate, and a pair of holding protrusions. The holding protrusions sandwich at least two parts of the lead wire to dispose the lead wire at a fixed position. Each of the holding protrusions has a holding gap sandwiching and holding the press-fitted lead wire. A connection space of the lead wire and the metal plate is provided between the holding protrusions. The lead wire is held on the surface of the metal plate with the holding protrusions and is connected to the surface of the metal plate in the connection space.