A Study of Optimal Structure Design for the Contact Spring Plates in a Spring Type Connector

目前常見之電子相關產品，其內部都具有連接功能的基本元件，此連接元件即為連接器，連接器在電子產品中扮演著相當於橋梁之重要角色。連接器內部裝設之端子接觸彈片因變形而產生正向力，而正向力大小將影響連接器傳遞電子訊號的能力，因此如何設計具有優良性能之接觸彈片成為一項非常重要的課題。 本論文首先針對常見的連接器材料建立機械性質，同時針對常見之一般金屬鍍層進行摩擦試驗以建立鍍層之摩擦係數。研究中同時針對已建立之材料機械性質進行接觸彈片性能影響性分析。研究中亦利用已建立之材料性質建立有限元素軟體之分析模式，並且針對實際量產之連接器載具進行分析模式之驗證。 為了解正向力對於連接器性能之影響性，本論文首先藉由文獻蒐集了解接觸電阻之特性。並且研究中已建立一接觸電阻特性實驗平台，藉由改變接觸形態與正向力大小，探討接觸電阻之特性。 本論文亦應用實驗設計法分析彈片結構對於連接器性能之影響，藉由結構分析模式的建立，能迅速掌握端子彈片之設計要點。論文中同時針對完整之彈片結構進行最佳化分析，最佳化分析之結果亦符合接觸電阻之最小正向力之要求。本研究所建立之分析流程期望未來可供業界應用之參考。In common, electronic products contain connective fundamental components which are called connectors. Connectors play an important role as a bridge in electronic products. Connectors are consisted of several terminal contact springs. After connecting, contact springs will deform and normal force will be generated. Furthermore, normal force affects how connectors send electronic signal. As a result, designing a high quality contact spring is a significant lesson. In this thesis, mechanical properties of common materials of connectors are established and the friction coefficient of different surface coating materials are obtained by experiment. Trough finite elements analysis, the overall analysis of connectors is established. The effect of mechanical properties of various materials can be investigated in the performance of contact springs. Finally, by comparison with computer analysis and experiments, accurate simulation can be achieved. In order to learn how’s the interaction between the characteristics of contact resistance and normal force, which affect the performance of connectors, associated research and papers are collected. Moreover, the experiment is established to investigate the relationship of various type of contact behaviors and the normal force. Therefore, through previous experimental data, the properties of contact resistance can be discussed. Design of Experiment (DOE) is a common analysis method which is applied in the thesis to analyze the effects of the structure of the springs. By establishing the analysis modality, the key parameters of designing terminal springs can be obtained. Optimal analysis is utilized to complete structure of springs. Consequently, the result of optimal analysis matches the contact resistance’s least normal force requests. The analysis procedures in the research will aim the industry as reference of design.目錄..............................I 圖目錄...........................IV 表目錄..........................VIII 第一章 緒論......................1 1.1 研究背景與目的..............1 1.2 研究方法與步驟..............3 1.3 文獻蒐集與歸納..............6 1.4 論文總覽...................9 第二章 連接器介紹.................10 2.1 連接器功能.................10 2.2 連接器結構.................12 第三章 連接器端子CAE模擬分析模式建立..18 3.1 有限元素分析軟體ABAQUS簡介....18 3.2 材料機械性質試驗.............20 3.3 連接器端子公母端子配合模擬建立..25 3.4 連接器模擬之簡化.............37 3.5 模擬分析驗證................44 第四章 接觸型態探討................51 4.1 接觸電阻理論................51 4.2 接觸電阻實驗................56 4.3 實驗結果探討................65 4.4 實驗問題與改善方法...........68 第五章 連接器材料影響分析...........70 5.1 連接器端子載具介紹...........70 5.2 材料性質對於性能影響之分析.....72 第六章 連接器結構造型最佳化設計......76 6.1 實驗設計法介紹..............76 6.2 分析步驟...................80 6.3 品質指標...................83 6.4 結構造型參數水準設計及直交表選用87 6.5 直交表分析..................90 6.6 彈片結構最佳化設計...........98 第七章 結論......................103 參考文獻...........................10