Terminal Support Resin Composite Thermal Stress
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Solution Overview
Problem
Conventional terminal-supporting apparatuses experience stress and potential damage due to thermal expansion and shrinkage of resin materials, leading to repeated stress on connecting portions between parallel terminal portions and electric elements.
Innovation Solution
A terminal-supporting apparatus using a non-conductive resin material with non-conductive reinforced fibers, such as glass fibers, whose thermal expansion coefficient is smaller than the resin material, is employed to support parallel terminal portions, aligning the fiber direction perpendicular to the terminal extensions, thereby reducing thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resin material is used to support parallel terminal portions, then ease of manufacture and electrical insulation are improved, but thermal expansion and shrinkage cause stress and potential damage to connecting portions
Solution Approach 1:
The resin material is combined with non-conductive reinforced fibers (such as glass fibers) to create a composite material. This composite maintains the ease of manufacture and electrical insulation properties of the resin while adding thermal stability through the fibers, which have a smaller thermal expansion coefficient than the resin alone.
Solution Approach 2:
The thermal expansion coefficient of the supporting material is changed by adding reinforced fibers. The fibers alter the physical parameters of the material, reducing the thermal expansion and shrinkage that occurs with temperature variations, thereby stabilizing the interval between terminal portions.
2Device complexity
If conventional resin material is used, then manufacturing simplicity is maintained, but repeated thermal stress damages the connecting portion between terminals and electric element
Solution Approach 1:
By incorporating non-conductive reinforced fibers into the resin, the material gains resistance to thermal stress while maintaining manufacturing simplicity. The fibers create a more stable composite structure that withstands repeated thermal cycles without damaging the terminal connections.
Solution Approach 2:
The reinforced fibers convert the potential harm of thermal expansion into a benefit by providing a stabilizing effect. The fibers restrict the resin's thermal expansion and shrinkage, transforming the material into one that resists thermal stress while maintaining the original manufacturing process.
3Ease of manufacture
If resin material with high thermal expansion coefficient is used, then ease of processing is improved, but interval between terminal portions varies due to thermal expansion and shrinkage
Solution Approach 1:
The resin composite with reinforced fibers maintains ease of processing while improving dimensional stability. The fibers embedded in the resin reduce thermal expansion and shrinkage, ensuring that the interval between terminal portions remains consistent even during temperature variations in the manufacturing process.
Solution Approach 2:
The thermal expansion coefficient parameter of the supporting material is modified by adding fibers. This parameter change reduces the variation in interval between terminal portions caused by thermal effects, thereby improving manufacturing precision without significantly complicating the processing.
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 configuration maintains a consistent interval between terminal portions, reducing physical stress on connecting points and enhancing the reliability of electronic components like rotational angle sensors and electronic throttles by minimizing thermal expansion and shrinkage effects.
Implementation Method 1
When the resin part 1 is heated or cooled, the resin material is thermally expanded or thermally shrunk. Due to the thermal expansion and thermal shrinkage, an interval between the parallel terminal portions α in the perpendicular direction γ is varied
Data Source
AI summary
A terminal-supporting apparatus includes a resin part made of non-conductive resin material and a plurality of conductive terminals including parallel terminal portions which are directly supported by the resin part. The parallel terminal portions are electrically connected to each other through an electric element. The resin part supporting the parallel terminal portions is made of non-conductive resin material mixed with non-conductive reinforced fibers of which thermal expansion coefficient is smaller than that of the non-conductive resin material. An extending direction of the parallel terminal portion is referred to as a longitudinal direction and a direction perpendicular to the longitudinal direction is referred to as a perpendicular direction. The non-conductive reinforced fibers have a fiber direction which is substantially the same as the perpendicular direction.