Connection Terminal Box Structure for Ultrasonic Bonding Durability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connection terminals with thin-walled portions for improved workability suffer from reduced strength, making them susceptible to damage during ultrasonic bonding, and require costly materials and methods to enhance durability.
Innovation Solution
A connection terminal design featuring thin-walled portions along bending parts, strategically arranged at a distance from the end portions, enhances workability and durability against ultrasonic bonding vibrations while allowing for cost-effective welding methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thin-walled portions are provided along the bending parts, then workability of the box unit is improved, but strength of the bending part decreases making it susceptible to damage during ultrasonic bonding
Solution Approach 1:
The patent applies local quality by providing thin-walled portions only at specific locations along the bending parts rather than uniformly throughout. The thin-walled portions are positioned at predetermined intervals and arranged at a distance from end portions, creating localized areas of reduced thickness that facilitate bending while preserving strength in critical regions. This selective thinning resolves the contradiction by making the box unit easier to manufacture where needed while maintaining structural integrity where required.
2Ease of manufacture
If thin-walled portions are provided along the bending parts, then bending workability is improved, but durability against ultrasonic bonding vibrations deteriorates
Solution Approach 1:
The patent implements local quality by strategically positioning thin-walled portions at specific intervals along the bending parts, arranged at a distance from end portions. This localized approach provides sufficient thinning to improve bending workability while avoiding excessive thinning in areas that would be vulnerable to ultrasonic bonding vibrations. The selective distribution of thin-walled portions resolves the contradiction between manufacturing ease and bonding durability.
Solution Approach 2:
The patent applies preliminary action by pre-positioning thin-walled portions at predetermined intervals and locations before the ultrasonic bonding process. By arranging these thin-walled portions at a distance from end portions in advance, the design anticipates and prevents potential damage during subsequent ultrasonic bonding operations, thereby improving durability while maintaining bending workability.
3Reliability
If joining material and method of welding are changed to satisfy strength requirements, then durability against ultrasonic bonding is improved, but cost becomes high
Solution Approach 1:
The patent applies parameter changes by modifying the geometric parameters of the box unit structure itself - specifically by controlling the thickness, position, and distribution of thin-walled portions along the bending parts. By optimizing these structural parameters, the patent achieves sufficient strength for ultrasonic bonding without needing to change the joining material or welding method, thereby avoiding increased costs. This resolves the contradiction by finding a cost-effective solution through structural optimization rather than material or process changes.
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 improves the strength and durability of the connection terminal's bending parts, reducing the risk of damage from ultrasonic bonding vibrations and enabling cost-effective bonding processes.
Implementation Method 1
when the electric wire is ultrasonically bonded in the electric wire connection part, it is possible that the box unit is damaged by the vibration of the ultrasonic wave
Data Source
AI summary
A connection terminal includes an electric wire connection part to which an electric wire is electrically connected by ultrasonic bonding, and an electric connection part integrated with the electric wire connection part and electrically connected to a mating terminal. The electric connection part includes a box unit which is formed in a cylindrical shape by bending a plurality of bending parts and into which the mating terminal is capable of being inserted, and a thin-walled portion having a thickness less than other parts of the box unit is continuously provided along each of the bending parts, and at least one of the thin-walled portions is arranged at a distance from an end portion of the box unit.