Terminal Connecting Structure Waterproofing via Dipping Method
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Solution Overview
Problem
Existing terminal connecting structures for grounding in automobiles require masking steps for water sealant application, increasing production costs and complexity, and do not allow for configurations without bolt tightening plates at the tip end.
Innovation Solution
A terminal connecting structure and method that uses a dipping method for waterproofing, eliminating the need for masking and enabling corrosion-proof connections by exposing conductor portions, crimping, and thermally bonding or ultrasonically connecting aluminum and copper wires to terminals, which are then fixed to a body panel without overlapping, allowing for easy disassembly and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If masking steps are used for water sealant application in existing terminal connecting structures, then waterproofing reliability is improved, but production cost and manufacturing complexity increase
Solution Approach 1:
The terminal body structure itself serves as the waterproofing container through its hollow configuration and integrated sealing features. The terminal body's own structure (including the hollow space, sealing ring groove, and positioning protrusions) performs the waterproofing function without requiring separate masking steps or additional waterproofing components, thereby reducing manufacturing complexity while maintaining waterproofing reliability
Solution Approach 2:
The terminal body is divided into functional segments: the hollow space for insulation, the sealing ring groove for waterproof sealing, and the positioning protrusion for precise alignment. This segmentation allows each feature to perform its specific function efficiently, achieving reliable waterproofing through structured design rather than process-intensive masking methods
2Reliability
If bolt tightening plates are added to terminal fixing portions for secure mounting, then mounting reliability is improved, but device complexity and production cost increase
Solution Approach 1:
The terminal body is designed to perform multiple functions: electrical connection, mechanical fixing, and waterproof sealing. The fixing portion with positioning protrusion serves both as a mounting feature and as a sealing interface, eliminating the need for separate bolt tightening plates and reducing overall structural complexity while maintaining mounting reliability
Solution Approach 2:
The fixing function and sealing function are merged into a single integrated terminal body structure. The positioning protrusion on the terminal body simultaneously provides mechanical alignment for mounting and creates a sealing interface for waterproofing, combining multiple functions into one component to reduce complexity
3Reliability
If aluminum and copper wires are directly connected to prevent galvanic corrosion, then electrical reliability is improved, but manufacturing complexity increases due to separate terminal requirements
Solution Approach 1:
The terminal body is designed with differentiated local properties: the first conductor receiving portion is optimized for aluminum wires with appropriate crimping features, while the second conductor receiving portion is optimized for copper wires. This local quality differentiation allows each material to be connected with its optimal method, ensuring electrical reliability while managing complexity through specialized design
Solution Approach 2:
The terminal body is segmented into distinct receiving portions for different conductor materials. The first portion handles aluminum conductors and the second portion handles copper conductors, with each portion having tailored internal features for optimal connection. This segmentation prevents galvanic corrosion by isolating dissimilar metals while maintaining manufacturing efficiency through a single integrated component
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 provides a cost-effective, waterproof, and corrosion-proof terminal connecting method that simplifies the manufacturing process by eliminating masking steps and ensuring reliable electrical connections while preventing galvanic corrosion between different metal conductors.
Implementation Method 1
a water sealant for molding the conductor connecting terminal
Implementation Method 2
the water sealant which covers the fixing-terminal connecting portion of the conductor connecting terminal contacting with the fixing terminal is melted and removed by heat due to the thermal bonding
Implementation Method 3
the water sealant which covers the fixing-terminal connecting portion of the conductor connecting terminal contacting with the fixing terminal is removed by vibrations and heat due to the ultrasonic connection
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A terminal connecting structure includes: an electric wire in which a conductor is covered by an insulative covering; a conductor connecting terminal to which a conductor exposed portion in which the covering of an end portion of the electric wire is removed and the conductor is exposed is electrically connected; a water sealant for molding the conductor connecting terminal; and a fixing terminal which includes a terminal fixing portion that is to be fixed and electrically connected to a mount part, and which is electrically connected to a part of the conductor connecting terminal in a state where the water sealant is removed from the part of the conductor connecting terminal.