Wire Harness Terminal Structure with Cylindrical Swaged Part
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Solution Overview
Problem
Existing in-vehicle wire harness terminal structures fail to achieve a sufficient anticorrosion effect due to incomplete resin molding on the terminal fitting's back surface, which allows electrolytic solutions to penetrate and corrode the exposed regions of the wire conductors.
Innovation Solution
A terminal structure with a swaged part on the terminal fitting, coated with molding resin over the entire outer circumference of the exposed end region and its adjacent areas, including a non-plated region, using materials like copper for the fitting and aluminum for the conductors, to prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal fitting is mounted on a flat surface with resin molding, then waterproof treatment is achieved, but the back surface of the terminal fitting is not completely resin-molded resulting in insufficient anticorrosion effect
Solution Approach 1:
The invention transitions from a two-dimensional flat surface mounting to a three-dimensional cylindrical configuration. The terminal fitting is formed in a cylindrical shape with the wire conductor passing through its center, allowing the molding resin to completely surround and coat the back surface area in all directions, achieving complete coverage that prevents corrosion.
Solution Approach 2:
The invention uses a composite structure combining the terminal fitting material (such as metal), the wire conductor material, and the molding resin material. This composite approach allows the resin to not only provide waterproofing but also complete anticorrosion protection by fully enclosing the back surface area of the terminal fitting.
2Shape
If the molding resin is applied to maintain flatness of the terminal fitting back surface, then flatness is preserved, but complete resin molding is compromised
Solution Approach 1:
The invention abandons the constraint of maintaining a flat back surface and instead adopts a cylindrical three-dimensional shape. This dimensional change allows the molding resin to completely surround the terminal fitting from all directions, achieving full coverage without being limited by flatness requirements.
3Reliability
If plating is applied to the entire terminal fitting surface, then corrosion resistance is improved, but manufacturing cost increases
Solution Approach 1:
The invention extracts or removes the plating process from the terminal fitting manufacturing. Instead of applying plating to the entire surface, the design relies on the molding resin to provide complete corrosion protection, eliminating the need for costly plating operations while maintaining effective corrosion resistance.
Solution Approach 2:
The molding resin acts as an intermediary protective layer between the terminal fitting and the corrosive environment. Rather than using plating as the primary protection method, the resin coating serves as a cost-effective mediator that provides complete coverage and corrosion protection.
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 effectively prevents corrosion by blocking electrolytic solutions from entering, maintaining the electrical integrity of the wire conductors and reducing manufacturing costs by eliminating the need for additional plating.
Implementation Method 1
a structure, which is resin-molded and is subjected to waterproof treatment
Implementation Method 2
a swaged part that is formed on one end and is fixed to the coated wire by being swaged along an outer circumference of the coating part
Implementation Method 3
the terminal fitting has a plated region formed by plating the surface of the terminal fitting
Data Source
AI summary
According to the present invention, in a terminal region of a coated wire, a swaged part formed at one end of a terminal fitting is swaged along an outer circumference of a coating part of the coated wire, and the terminal fitting is fixed to a terminal section of the coated wire. A molding resin is formed so as to completely coat the entire outer circumference of an exposed end region (a region including a fracture surface and a base edge) of the swaged part and its adjacent region.