Solder Connecting Member Bulging Wire Branch Circuit
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Solution Overview
Problem
Existing electrical connection assemblies in automotive vehicles require special components and increased manufacturing costs and time to form branch circuits, hindering production efficiency.
Innovation Solution
The use of solder-based connecting members with bulging portions to connect wires directly to terminals, eliminating the need for additional special members and allowing for efficient connection of wires within a simple structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If special components and structures are used to form branch circuits, then connection reliability is improved, but manufacturing cost and device complexity increase significantly
Solution Approach 1:
The patent merges the functions of wire connection and branch circuit formation into a single integrated connector structure. The connecting members made of solder material are formed with bulging portions that simultaneously connect multiple wires to terminals, eliminating the need for separate special components. This integration maintains connection reliability while reducing device complexity.
Solution Approach 2:
The connecting members serve multiple functions: they act as both connection elements for wires to terminals and as branch circuit formers. The bulging portions enable a single connecting member to connect multiple wires, providing multi-functionality that reduces the need for specialized components while maintaining reliable electrical connections.
2Reliability
If special components and structures are used to form branch circuits, then connection reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the physical parameters of the connecting members by forming bulging portions through plastic deformation or additive processes. This parameter change allows the same base material to serve multiple connection functions, eliminating the need for expensive special components while maintaining reliable connections. The solder material properties are utilized to achieve both mechanical strength and electrical conductivity.
Solution Approach 2:
The patent uses standard solder material and connecting members that can be mass-produced at low cost, replacing expensive special components. The connecting members are designed to be functional rather than durable, suitable for single-use in mass production, which significantly reduces manufacturing cost while maintaining adequate connection reliability.
3Adaptability or versatility
If methods (i) or (iii) are used for mutual connection, then connection functionality is achieved, but production efficiency decreases due to increased man-hours
Solution Approach 1:
The bulging portions are pre-formed on the connecting members before assembly, so that the multi-functional connection capability is prepared in advance. This preliminary action allows workers to simply assemble the connector without performing additional complex operations for branch circuit formation, thereby maintaining connection functionality while significantly improving production efficiency.
Solution Approach 2:
The connecting members with bulging portions automatically provide the branch circuit formation function during the normal wire connection process. The structure self-services by integrating multiple functions into a single component, eliminating the need for separate manual operations or additional specialized components, thus improving productivity without sacrificing adaptability.
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 approach enables reliable and efficient connection of wires without significant cost increases, improving production efficiency by using solder to form bulging portions that directly connect wires, enhancing connection reliability and simplifying the manufacturing process.
Implementation Method 1
The connecting member is formed from solder and therefore has a high degree of shape freedom. Thus, by devising the shape, the conductors of the specific wires can be connected without adding a special member.
Implementation Method 2
cream solder is set in advance on surfaces of the terminals, and the tips of the conductors and the surfaces of the terminals are soldered by pressing the tips of the conductors of the terminals against the surfaces of the terminals by a heater with the tips of the conductors positioned on the cream solder. The cream solder then is heated.
Data Source
AI summary
An electrical connection assembly and a connection method enable conductors of first and second wires (10A, 10B) to be connected by a simple structure. The electrical connection assembly has first and second wires (10A, 10B) and first and second terminals (20A, 20B) corresponding to the first and second wires (10A, 10B). First and second connecting members (70A, 70B) made of solder are fixed to wire connection surfaces (27a) of the first and second terminals (20A, 20B), and an insulating housing holds the terminals. The first connecting member (70A) includes a bulging portion (72A) bulging from the wire connection surface (27a) of the first terminal (20A) and to be connected electrically to the conductor of the second wire (10B).