Terminal Production via Segmented Tapered Surface Formation

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Solution Overview

Problem

Conventional methods for cutting unit-length pin contacts from a pin contact wire result in material waste and require multiple production steps, leading to low productivity and inefficient use of material.

Innovation Solution

Forming tapered surfaces only at the end portions of a linear conductive material with a square cross-section, allowing for a reduced terminal length with an effective winding region, and using a simplified two-step process with forming dies to cut out terminals, which can include annular or protruded designs for enhanced press fitting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If tapered surfaces are formed by butting forming dies against the pin contact wire to prevent scraping, then the inner peripheral surface of the terminal hole is protected, but the effective winding region is reduced and material is wasted

Engineering Contradiction:

Improveprotection of inner peripheral surfaceVSAvoidmaterial waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The tapered surface formation is segmented from the main cutting process. Instead of forming tapered surfaces along the entire length of the pin contact wire, the invention forms tapered surfaces only at the end portions after cutting unit-length terminals. This segmentation allows the effective winding region to be maximized while still providing protection against scraping at the critical insertion points.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cutting process is performed as a preliminary action before forming the tapered surfaces. By first cutting the unit-length terminals from the pin contact wire and then forming tapered surfaces only at the end portions, the invention avoids material waste along the entire length while ensuring protection where needed for the press-fitting process.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If multiple forming dies are butted against the pin contact wire to form tapered surfaces, then the terminal hole is protected from scraping, but the number of production steps increases and productivity decreases

Engineering Contradiction:

Improveprotection of inner peripheral surfaceVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention merges the cutting process and tapered surface formation process into a more integrated workflow. By cutting unit-length terminals first and then forming tapered surfaces only at the end portions in a subsequent step, the process reduces the number of separate operations compared to continuously forming tapered surfaces along the entire wire length before cutting, thereby improving productivity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The tapered surface formation is extracted from the main cutting process and applied only to the end portions of the cut terminals. This extraction eliminates the need for multiple forming dies to operate along the entire length of the wire, reducing equipment complexity and production steps while maintaining the protective function where needed.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If tapered surfaces are formed along the entire length of the pin contact wire, then the terminal is protected from scraping, but the effective winding region is reduced requiring extra length

Engineering Contradiction:

Improveprotection against scrapingVSAvoidterminal length

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The invention applies local quality by forming tapered surfaces only at the end portions of the unit-length terminals rather than along the entire length. This localized application of tapered surfaces provides protection against scraping at the critical insertion points while preserving the maximum possible effective winding region along the body of the terminal, thereby minimizing the required terminal length.

Inventive Principle:

Principle #3Local quality

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 minimizes material waste, reduces production steps, and enhances productivity by allowing for smoother press fitting and improved assembly performance, while maintaining the integrity of the terminal's inner surface.

Implementation Method 1

forming cutting recesses on ridge lines of the linear conductive material by first pressing surfaces, each provided on each of the butt surfaces; forming tapered surfaces continuous with the cutting recesses by second pressing surfaces

Methodology Applied

Scientific EffectPlasticity: Plasticity

Data Source

PatentUS8341999B2Terminal and method for producing the same

Publication Date: 2013.01.01 OMRON CORP

AI summary

A method for producing a terminal has the steps of disposing butt surfaces of a pair of forming dies and side surfaces of a linear conductive material having a square shape in cross section parallel to one another, forming cutting recesses on ridge lines of the linear conductive material by first pressing surfaces, each provided on each of the butt surfaces, forming tapered surfaces continuous with the cutting recesses by second pressing surfaces, each formed by cutting at least one side edge portion of the first pressing surface, and cutting the cutting recesses so that a unit-length terminal is cut out.