Weld Tab Wire Squeeze Limiter for Solenoid Terminals
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Solution Overview
Problem
Existing electrical connection terminal technologies face challenges in securely and efficiently connecting wires to solenoid coil posts, particularly in ensuring proper pressure distribution during welding to avoid damaging the insulation and ensuring strong, reliable connections.
Innovation Solution
The development of an electrical connection terminal with a weld tab featuring a magnetic wire squeeze limiter, comprising planar portions that are not in the same plane, which limits pressure applied during welding and includes a coined portion to prevent excessive force on the wire, allowing for secure welding to both the post and the wire wrapped around it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal is welded to a wire wrapped around a post, then electrical connection is established, but excessive pressure during welding may damage the wire insulation
Solution Approach 1:
The patent introduces a wire squeeze limiter as an intermediary component between the welding terminal and the wrapped wire. This limiter acts as a protective mediator that controls and distributes the pressure applied during welding, preventing direct excessive force from damaging the wire insulation while still allowing sufficient pressure for reliable electrical connection.
Solution Approach 2:
The wire squeeze limiter modifies the pressure parameter during the welding process. By changing the physical state and distribution of force through its coined portion geometry, it transforms the welding pressure from a concentrated harmful force into a distributed controlled force that achieves connection without damage.
2Ease of manufacture
If uniform pressure is applied during welding, then the welding process is simple, but pressure distribution may be insufficient to ensure strong connections at both the post and wire interfaces
Solution Approach 1:
The welding terminal incorporates local quality variations through its coined portion with different planar surfaces at different heights. This creates localized pressure zones that concentrate force where needed - against the post at one interface and against the wrapped wire at another interface - ensuring strong connections at both locations while maintaining a relatively simple overall welding process.
3Ease of manufacture
If the weld tab is planar, then manufacturing is simple, but it cannot effectively limit pressure or prevent excessive force on the wire
Solution Approach 1:
The wire squeeze limiter incorporates a coined portion with pre-formed geometric features during manufacturing. This preliminary action creates built-in pressure-limiting structures that will automatically function during welding without requiring additional components or complex processes, thus maintaining manufacturing simplicity while achieving wire protection.
Data Source
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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.