Terminal-Attached Electric Wire Resin Separation Prevention
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Solution Overview
Problem
Conventional terminal-attached electric wires face issues with resin separation from terminals during die release, leading to potential water ingress and corrosion due to strong adhesion between the resin and molding die, rather than the terminal.
Innovation Solution
Incorporating a separation preventing portion with tapered surfaces inclined towards the tip side of the resin portion, which reduces shearing adhesion forces and minimizes external force reception, preventing resin separation from the terminal during die release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the adhesion between the resin portion and the terminal is strengthened to prevent separation, then the resin portion sticks to the molding die instead, making manufacturing difficult
Solution Approach 1:
The invention divides the resin portion into two functional zones: a base portion with strong adhesion to the terminal and a tip portion with a separation preventing portion that has reduced adhesion to the die. This segmentation allows the resin to exhibit different adhesion characteristics in different regions, solving the contradiction between preventing resin-terminal separation and enabling easy die release.
Solution Approach 2:
The invention applies local quality by creating a separation preventing portion with specific structural characteristics (reduced adhesion properties) only in the tip portion of the resin, while maintaining strong adhesion in the base portion. This localized modification allows the resin to prevent separation where needed without sticking to the die during manufacturing.
2Ease of manufacture
If the adhesion between the resin portion and the terminal is weakened to enable easy die release, then the resin portion separates from the terminal when external force acts on it
Solution Approach 1:
The resin portion is segmented into a base portion that maintains strong adhesion to the terminal and a tip portion containing a separation preventing portion with reduced die adhesion. This segmentation ensures that overall adhesion strength is sufficient to prevent separation under external force while the specific separation preventing portion enables easy die release.
Solution Approach 2:
The invention modifies only the local properties of the tip portion of the resin by introducing a separation preventing portion with reduced adhesion to the die, while the base portion retains strong adhesion characteristics. This localized approach prevents resin-terminal separation under external force while facilitating easy die release during manufacturing.
3Reliability
If the resin portion is molded with strong adhesion to prevent separation, then the resin portion separates from the terminal in the die release direction
Solution Approach 1:
The resin portion is divided into functional segments: a base portion that ensures reliable coverage of the conductor-exposed portion and strong adhesion to the terminal, and a tip portion with a separation preventing portion that reduces adhesion to the die. This segmentation resolves the contradiction between preventing corrosion and improving manufacturing efficiency.
Solution Approach 2:
The invention introduces a separation preventing portion with modified adhesion properties in the tip portion of the resin, while maintaining strong adhesion and protective function in the base portion. This local modification ensures both corrosion prevention and manufacturing efficiency without compromising the protective function.
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 effectively prevents resin separation from the terminal, reducing the risk of water ingress and enhancing the durability of the electric wire by ensuring the resin portion remains securely attached to the terminal, even under external forces.
Implementation Method 1
the adhesion between the resin portion and the terminal is too strong in molding the resin portion, the resin portion is stuck to the molding die rather than the terminal
Implementation Method 2
the separation preventing portion includes a tapered portion which is inclined toward a tip side of the resin portion... the shearing adhesion force that acts on the resin portion is weaker
Data Source
AI summary
In a terminal-attached electric wire (1), a resin portion (4) which covers a conductor-exposed portion of a terminal (3) to which a conductor is connected is formed by molding resin in the conductor-exposed portion. In the terminal-attached electric wire (1), the resin portion (4) has a peeling preventive portion (14) which prevents the resin portion (4) from peeing off in a release direction of a die when the die is released.