Terminal-attached Electric Wire Vibration Damping
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Solution Overview
Problem
Conventional terminal-attached electric wires face challenges in maintaining appropriate conduction performance after ultrasonic welding, particularly due to deformation and stress on the metal terminals during vibration, which can lead to reduced connection reliability.
Innovation Solution
A terminal-attached electric wire design featuring a metal terminal with a box-shaped portion and a spring contact portion, where the box-shaped portion includes a displacement regulating mechanism, such as a clamping portion or recess and protrusion, to manage relative displacement between wall bodies, ensuring stable contact and resistance to deformation during ultrasonic bonding and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ultrasonic welding is performed on the terminal-attached electric wire, then the electric wire can be connected to the terminal, but the metal terminal deforms and experiences stress reducing connection reliability
Solution Approach 1:
The patent applies beforehand cushioning by designing a vibration damping portion with a specific structure that absorbs and dissipates ultrasonic vibration energy before it can cause excessive deformation to the metal terminal. The vibration damping portion includes a deformation region that selectively yields during ultrasonic welding, protecting the terminal's critical dimensions from harmful stress while maintaining connection reliability
Solution Approach 2:
The patent applies parameter changes by modifying the physical structure of the terminal to include a vibration damping portion with specific material properties and geometric characteristics. This portion has controlled rigidity and damping characteristics that change how the terminal responds to ultrasonic vibrations, reducing deformation without compromising the welding process effectiveness
2Manufacturing precision
If the terminal structure is made rigid to maintain shape, then manufacturing precision is improved, but the terminal becomes more susceptible to stress and deformation during ultrasonic vibration
Solution Approach 1:
The patent applies local quality by creating a vibration damping portion with locally modified properties within the terminal structure. This portion has different rigidity and damping characteristics compared to the rest of the terminal, allowing it to absorb vibrations locally while the critical connection regions maintain their structural integrity and dimensional precision
Solution Approach 2:
The vibration damping portion is designed beforehand to cushion and absorb ultrasonic vibrations before they can propagate through the terminal and cause deformation. This pre-positioned damping structure protects the terminal's rigid portions from stress while maintaining manufacturing precision in critical areas
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 design effectively maintains appropriate conduction performance and connection reliability by regulating relative displacement and suppressing excessive deformation of the metal terminal, even under ultrasonic vibrations, thereby ensuring consistent electrical conductivity.
Implementation Method 1
a spring contact portion that is located inside the terminal insertion space portion, is elastically deformably supported in the box-shaped portion in a cantilever manner, and forms a contact with the counterpart terminal
Implementation Method 2
a terminal-attached electric wire welding method for performing ultrasonic welding for a terminal-attached electric wire
Data Source
AI summary
In a terminal-attached electric wire applied to a wire harness, a metal terminal includes: an electric wire connection portion to which the electric wire is connected; a box-shaped portion that is formed into a box shape by a bottom body coupled to the electric wire connection portion and a pair of wall bodies formed by protruding individually from both ends of the bottom body in a width direction, and enables a counterpart terminal to be inserted into a terminal insertion space portion in an inside thereof along an axial direction intersecting the width direction; and a spring contact portion that is located inside the terminal insertion space portion, is elastically deformably supported in the box-shaped portion in a cantilever manner, and forms a contact with the counterpart terminal, and wherein the box-shaped portion has a displacement regulating portion that regulates a relative displacement between the pair of the wall bodies.