Terminal Spring Portion Vibration Resistance Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing terminals with beam-shaped spring portions are prone to deterioration and plastic deformation due to vibrations during ultrasonic bonding, which can compromise the reliability of electrical connections.
Innovation Solution
A terminal design featuring a tubular box portion with a beam-shaped spring portion and a pressing piece that restricts the bending range of the spring portion, keeping the free end inside the box and closer to the base than the contact point, thereby limiting deformation and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a beam-shaped spring portion is used in the terminal, then the terminal can provide elastic contact force and maintain electrical connection, but the spring portion is prone to deterioration and plastic deformation due to vibrations during ultrasonic bonding
Solution Approach 1:
The spring portion is divided into multiple segments or sections with different structural characteristics. The fixed end portion has enhanced rigidity to resist vibration, while the free end maintains elasticity for contact force. This segmentation allows different parts of the spring to perform specialized functions, improving overall durability against vibration while maintaining electrical connection reliability.
Solution Approach 2:
The spring portion employs asymmetric cross-sectional geometry, with different moment of inertia values along its length. The fixed end portion has a larger cross-sectional area or thicker structure to provide higher bending resistance, while the free end has a smaller cross-section to maintain flexibility. This asymmetric design optimizes the distribution of mechanical properties along the spring, enhancing vibration resistance without compromising contact force.
2Ease of operation
If the spring portion is allowed to bend freely to provide elastic recovery, then contact force can be maintained, but excessive bending due to vibration causes deterioration and plastic deformation
Solution Approach 1:
The spring portion is designed with dynamic characteristics that allow controlled motion. The structure transitions from a simple static beam to a dynamic system with optimized natural frequency and damping properties. By tuning the spring's dimensional parameters and material properties, the design allows necessary elastic deformation for contact while minimizing resonance and excessive vibration response, thereby extending service life.
Solution Approach 2:
The spring portion's geometric parameters are optimized to balance elasticity and vibration resistance. Specific dimensional ratios, such as the length-to-thickness ratio and cross-sectional dimensions, are carefully selected to provide adequate elastic recovery for contact force while increasing resistance to vibration-induced deformation. Material parameters such as elastic modulus and damping ratio are also selected to achieve the desired balance between flexibility and durability.
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 terminal design significantly reduces deterioration and deformation of the spring portion under external vibrations, improving the reliability and durability of electrical connections and allowing for a more compact terminal structure.
Implementation Method 1
the spring portion being configured to elastically deform in a bending direction away from the mating terminal upon the mating terminal coming into contact with the contact point
Implementation Method 2
there is a case where ultrasonic bonding processing is performed in a state where conductor core wires of both electric wires are brought into close contact with each other, and both conductor core wires are bonded
Data Source
AI summary
A terminal includes: a tubular box portion to receive a mating terminal; a spring portion extending in a beam shape from a front end portion of the box portion; and a pressing piece configured to restrict a bending range of the spring portion. A free end of the spring portion is inside the box portion, and the spring portion has a contact point with the mating terminal. The pressing piece is placed at a pressing position located inside the box portion and away from the contact point in the bending direction. The pressing piece is configured to restrict the bending range of the spring portion to achieve at least part of the spring portion closer to the free end than the contact point is located on the bending direction side with respect to the pressing position.