Metal-Resin Connector Interface for Thermal Expansion and Vibration
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Solution Overview
Problem
The integration of a synthetic resin terminal holding member and a metal case in connectors leads to thermal expansion differences, causing clearance and vibration issues, which can result in solder cracks and the need for anti-vibration measures.
Innovation Solution
Incorporating a displacement restricting portion with an irregular shape on the metal case's contact surface with the synthetic resin terminal holding member, which suppresses relative displacements and enhances anchoring effects, thereby minimizing clearance and improving anti-vibration performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the case is made of metal to improve heat dissipation, then thermal conductivity is improved, but clearance is formed between the metal case and synthetic resin terminal holding member due to thermal expansion difference
Solution Approach 1:
The invention introduces a displacement restricting portion with an irregular shape on the contact surface of the metal case. This structural modification changes the physical parameters of the interface between metal and synthetic resin, allowing the irregular shape to engage with corresponding features on the terminal holding member. This engagement mechanically compensates for the dimensional changes caused by thermal expansion differences, maintaining tight fit and preventing clearance formation while preserving the metal case's superior heat dissipation capability
2Productivity
If the case made of metal and terminal holding member made of synthetic resin are integrated by insert molding, then manufacturing efficiency is improved, but clearance is formed due to difference in coefficient of linear expansion
Solution Approach 1:
The displacement restricting portion with irregular shape is incorporated into the insert molding process. The irregular shape features are molded directly into the metal case, and corresponding features are formed on the synthetic resin terminal holding member. During the insert molding integration process, these irregular shape features engage with each other, mechanically constraining relative displacement and preventing clearance formation while maintaining the efficiency of the integrated manufacturing process
3Temperature
If clearance is formed between terminal holding member and case, then anti-vibration performance deteriorates, but making the case of metal was intended to improve heat dissipation
Solution Approach 1:
The displacement restricting portion with irregular shape creates mechanical interlocking between the metal case and synthetic resin terminal holding member. This interlocking structure physically restricts relative displacement and vibration of the components while preserving the metal case's thermal conductivity. The irregular shape features engage to dampen vibrations and prevent the terminal holding member from moving independently, thereby maintaining both heat dissipation performance and anti-vibration reliability
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 solution effectively suppresses relative displacements between the metal case and synthetic resin terminal holding member, enhancing anti-vibration performance by restricting vibrations transmitted through the connector.
Implementation Method 1
a clearance may be formed between the terminal holding member and the case due to a difference between a coefficient of linear expansion of the metal and that of the synthetic resin
Data Source
AI summary
It is aimed to improve anti-vibration performance. A connector includes a terminal holding member made of synthetic resin for holding terminal fittings and a case made of metal for accommodating one end part of each terminal fitting by being integrated with the terminal holding member. The case includes a displacement restricting portion having an irregular shape, and the displacement restricting portion is formed on a contact surface of the case with the terminal holding member. When the case made of metal and the terminal holding member made of synthetic resin are thermally deformed, an anchoring effect by the engagement of the displacement restricting portion and the terminal holding member is achieved on the contact surface of the case with the terminal holding member to suppress relative displacements between the case and the terminal holding member.