Press Bond Terminal With Projections For Core Wire Alignment

Solution Overview

Problem

Conventional press bond terminals face challenges in achieving a balance between stable electrical connection performance and mechanical connection strength, as strong press bonding can lead to excessive bonding that breaks the core wire, while weak crimping results in unstable electrical connections.

Innovation Solution

A press bond terminal with a conductor press bond part featuring a U-shaped cross section and a projection on its inner surface, which can be a continuous projecting bar or multiple spaced projections, to increase internal stress and improve grip force on the conductor wire, enhancing compatibility between electrical and mechanical connection performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If strong press bonding is applied to ensure stable electrical connection performance, then electrical connection stability is improved, but the core wire may break due to excessive bonding force, reducing mechanical connection strength

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidmechanical connection strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The base plate incorporates projections at specific locations (center and/or corners) that create localized stress concentration points. These projections are strategically positioned to generate internal stresses that prevent core wire misalignment and breakage during crimping, while allowing uniform stress distribution in other areas to maintain electrical connection stability without excessive bonding force.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention changes the structural parameters of the base plate by adding projections with specific dimensions (height of 0.1-0.5mm, width of 0.5-2.0mm). These parameter modifications create controlled internal stress fields that improve both electrical connection reliability and mechanical strength, resolving the contradiction between stable electrical connection and prevention of core wire breakage.

Inventive Principle:

Principle #35Parameter changes

2Strength

If weak crimping is applied to avoid excessive bonding, then core wire breakage is prevented, but fastening strength becomes insufficient, reducing mechanical connection strength

Engineering Contradiction:

Improvefastening strengthVSAvoidelectrical connection stability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The projections are strategically positioned at the center and/or corners of the base plate to create localized stress concentration zones. These zones generate internal stresses that enhance grip force on the conductor, ensuring adequate fastening strength even with weaker crimping forces, while preventing core wire misalignment that could compromise electrical connection stability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

By modifying the base plate structure with projections of specific dimensions, the invention changes the stress distribution parameters during crimping. This allows achieving sufficient fastening strength with reduced crimping force, thereby preventing core wire breakage while maintaining electrical connection reliability.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If conventional U-shaped conductor press bond part is used, then manufacturing is simple, but grip force on conductor is insufficient and misalignment between core wires occurs, reducing electrical connection stability

Engineering Contradiction:

Improvestructural simplicityVSAvoidelectrical connection stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The base plate incorporates projections at specific locations (center and/or corners) that create localized stress concentration points. These projections are strategically positioned to generate internal stresses that prevent core wire misalignment and breakage during crimping, while allowing uniform stress distribution in other areas to maintain electrical connection stability without excessive bonding force.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention changes the structural parameters of the base plate by adding projections with specific dimensions (height of 0.1-0.5mm, width of 0.5-2.0mm). These parameter modifications create controlled internal stress fields that improve both electrical connection reliability and mechanical strength, resolving the contradiction between stable electrical connection and prevention of core wire breakage.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS8905799B2Press bond terminal

Publication Date: 2014.12.09 YAZAKI CORP

AI summary

An object of the invention is to provide a press bond terminal capable of easily ensuring compatibility between electrical connection performance and mechanical connection performance in the case of connecting a terminal to an electric wire. In a press bond terminal (10) having a conductor press bond part (13) connected by being pressed and bonded to a distal end of a conductor (Wa) of an electric wire, the conductor press bond part (13) being formed in substantially a U-shaped cross section by a base plate (13A) and a pair of conductor crimp pieces (13B) which is extended upward from both right and left lateral edges of the base plate (13A) and is crimped so as to wrap the conductor (Wa) disposed on an inner surface of the base plate (13A), an inner surface of the base plate (13A) of the conductor press bond part (13) is provided with a projecting bar (22).