Standing Terminal Weld Layout for Spatter-Blocking Electrical Assemblies
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Solution Overview
Problem
Welding spatter in electrical apparatuses poses a challenge as it can adhere to other components, causing problems during the welding process, and existing solutions are difficult to apply effectively to terminal portions.
Innovation Solution
The electrical apparatus design includes a first and second welded member with metal and resin parts, where the resin parts partially overlap and a surrounding jig is used to contain the weld area, blocking spatter and limiting its scattering region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is performed to join metal parts, then joining strength is improved, but welding spatter scatters and adheres to other parts causing contamination
Solution Approach 1:
A resin part is introduced as an intermediary component between metal parts to be welded. The resin part covers the metal part and has a designated area where welding spatter can adhere, preventing spatter from contaminating other parts of the electrical apparatus. This intermediary structure allows the welding process to proceed while containing the harmful spatter effect.
Solution Approach 2:
The harmful spatter adhesion function is extracted and assigned to a specific designated area on the resin part, separate from the metal parts and other sensitive components. By isolating the spatter reception function to a specific location, the contamination problem is contained and does not affect other parts of the apparatus.
2Object-affected harmful factors
If resin parts are added to cover metal parts, then spatter contamination is reduced, but device complexity increases
Solution Approach 1:
The resin part serves multiple functions: it provides electrical insulation for the metal part, structural support, and a designated spatter reception area. By combining these functions into a single component, the design avoids adding separate elements for each function, thereby limiting the increase in device complexity while achieving spatter containment.
Solution Approach 2:
The spatter protection function is merged with the existing resin part structure rather than being implemented as a separate component. The resin part is designed to integrate both its original protective/insulating function and the new spatter reception function, reducing overall structural complexity compared to adding a separate spatter shield.
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 effectively suppresses the influence of welding spatter on components by blocking it with overlapping resin parts and a surrounding jig, ensuring a cleaner weld area and reduced spatter impact.
Implementation Method 1
placing a surrounding jig around the first standing terminal portion and the second standing terminal portion so as to surround at least the welded portions of the first and second standing terminal portions from directions perpendicular to the standing direction
Implementation Method 2
The first resin part and the second resin part partially overlap each other in the standing direction. The weld is within a projection region of the first resin part and the second resin part in the standing direction
Data Source
AI summary
An electrical apparatus includes first and second welded members that are welded together. The first welded member has a first metal part and a first resin part covering part of the first metal part. The second welded member has a second metal part and a second resin part covering part of the second metal part. The first metal part has a first standing terminal portion exposed from the first resin part and standing in a standing direction. The second metal part has a second standing terminal portion exposed from the second resin part and standing in the standing direction. The first and second standing terminal portions are welded to each other so that a weld is formed therebetween. The first and second resin parts partially overlap each other in the standing direction. The weld is within a projection region of the first and second resin parts in the standing direction.