Wire Harness Connector Layout for Uniform Multi-Terminal Soldering
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Solution Overview
Problem
Conventional methods of soldering multiple conductive members to a rigid-flexible board result in varying precision, leading to potential inconsistencies.
Innovation Solution
A wire harness design featuring a connector with a terminal holding part and a planar routing member, where terminals are arranged in staggered rows and connected to a flexible printed board via through holes, allowing for collective laser-irradiated soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If soldering is performed for each conductive member individually, then each terminal can be connected separately, but soldering precision varies and consistency deteriorates
Solution Approach 1:
The patent merges multiple individual soldering operations into a single collective soldering process. The planar routing member is designed with multiple through-holes that accommodate multiple terminals simultaneously, allowing all terminals to be soldered to the flexible printed board part in one operation. This eliminates the variation in soldering precision that occurs when each terminal is soldered separately, ensuring consistent soldering quality across all conductive members.
Solution Approach 2:
The patent implements preliminary positioning of terminals using the terminal holding part, which holds multiple terminals in predetermined positions before soldering. The planar routing member is also designed with through-holes at predetermined locations that correspond to terminal positions. This preliminary arrangement ensures that when collective soldering is performed, all terminals are correctly positioned, achieving both high precision and consistency.
2Ease of manufacture
If multiple terminals are soldered individually to a rigid-flexible board, then each connection can be made separately, but the process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple separate soldering operations into a single collective soldering process. The planar routing member with its structured through-holes and the terminal holding part work together to enable all terminals to be soldered to the flexible printed board part simultaneously. This merging of operations simplifies the manufacturing process and significantly reduces the time required compared to individual soldering of each terminal.
3Adaptability or versatility
If terminals are arranged in multiple rows, then connectivity increases, but alignment precision becomes more difficult to maintain
Solution Approach 1:
The patent uses the terminal holding part to preliminarily position multiple terminals in precise multi-row arrangements before soldering. The holding part ensures correct spacing and alignment of terminals in multiple rows. Additionally, the planar routing member is designed with through-holes at predetermined positions that correspond to the terminal arrangements, maintaining alignment precision even when multiple rows of terminals are used.
Solution Approach 2:
The patent applies local quality by providing specific structural features at critical locations. The terminal holding part has predetermined positions that ensure precise local positioning of each terminal. The planar routing member has through-holes with specific dimensions and positions that match the terminal arrangements. This localized precision control maintains alignment accuracy across multi-row terminal configurations.
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
Ensures uniform and precise soldering of multiple terminals to the planar routing member, reducing size and complexity while enhancing connectivity and stability.
Implementation Method 1
the flexible printed board part is disposed to cover an end surface from which the insertion portions of the plurality of terminals protrude in the terminal holding part, and is physically and electrically connected to the insertion portions via solders
Data Source
AI summary
A wire harness includes: a connector including a plurality of terminals having insertion portions, and a terminal holding part that holds the plurality of terminals arranged in a plurality of rows in a state where the insertion portions protrude therefrom; and a planar routing member including a flat plate-shaped flexible printed board part having flexibility, with a plurality of through holes formed therein to be physically and electrically connected to the terminals through the through holes, in which the flexible printed board part is disposed to cover an end surface from which the insertion portions of the plurality of terminals protrude in the terminal holding part, and is physically and electrically connected to the insertion portions via solders in a state where the insertion portions of the terminals corresponding to the plurality of through holes are inserted into the plurality of through holes, respectively.