Weld Tab Wire Squeeze Limiter for Solenoid Valves
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connection terminals face challenges in securely welding to wires around solenoid coil posts without damaging the insulation or applying excessive pressure, which can lead to unreliable connections and potential damage.
Innovation Solution
The development of an electrical connection terminal with a weld tab featuring a coined portion that includes substantially planar first and second portions not in the same plane, acting as a magnetic wire squeeze limiter, limits pressure applied during welding and ensures secure attachment to both the post and wire, while also accommodating wires with insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal is welded to a wire wrapped around a solenoid coil post, then secure electrical connection is achieved, but excessive pressure may damage the wire insulation
Solution Approach 1:
The coined portion of the weld tab acts as an intermediary element between the welding electrode and the wire. During welding, the coined portion deforms first to absorb excess pressure, preventing direct transmission of harmful forces to the wire insulation. This mediator structure ensures secure electrical connection while protecting the insulation from damage.
Solution Approach 2:
The coined portion is pre-formed with a reduced cross-sectional area, creating a built-in cushioning zone before welding occurs. This pre-engineered weak point is designed to deform during welding, absorbing pressure spikes and protecting the wire insulation from excessive forces before damage can occur.
2Ease of manufacture
If a weld tab is designed with planar portions for welding, then weldability is improved, but pressure distribution during welding becomes concentrated
Solution Approach 1:
The weld tab features different local geometries: planar portions for optimal welding contact and a coined portion with reduced cross-section for pressure absorption. This local quality variation allows the tab to provide both excellent weldability and pressure distribution, with each zone performing its specific function during the welding process.
3Reliability
If wire insulation is present during welding, then complete electrical connection is achieved, but welding pressure may compromise insulation integrity
Solution Approach 1:
The coined portion serves as a protective intermediary between the welding pressure and the wire insulation. It deforms preferentially during welding, absorbing excess forces and preventing them from reaching the insulation. This allows complete electrical connection to be achieved while maintaining insulation integrity.
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 design enhances the reliability of electrical connections by preventing damage to insulated wires and ensuring a secure weld, maintaining the integrity of the insulation and the connection, thus improving the durability and performance of solenoid valve systems.
Implementation Method 1
The weld tab includes a magnetic wire squeeze limiter
Implementation Method 2
The substantially planar first portion is welded to the exposed portion of the post. The substantially planar second portion is welded to the portion of the wire wound around the post
Data Source
AI summary
One embodiment includes an electrical connection terminal (20) including at least a first weld tab (22). The first weld tab (22) including an outer face (23) and a weldable inner face (33). The weldable inner face (33) includes a substantially planar first portion (25) and a substantially planar second portion (27), and wherein the first portion (25) and second portion (27) are not in the same plane.