3D Terminal Fitting Layout for Higher Conductor Plate Yield
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Solution Overview
Problem
Existing terminal fittings discard a significant amount of conductor plate material between tab portions due to their design, leading to reduced material yield during manufacturing.
Innovation Solution
A terminal fitting design where first and second tab portions are arranged in a three-dimensional configuration, with the second tab portions accommodated in gaps between adjacent first tab portions and vice versa, allowing for a continuous conductor plate to be used without waste, and a method to manufacture this configuration by bending a preformed body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal fitting is designed with first tab portions and second tab portions extending in opposite directions from the main body portion in the preliminary shape, then the terminal fitting can be used as a ground terminal for grounding multiple circuits, but a significant amount of conductor plate material positioned between adjacent tab portions is discarded as waste
Solution Approach 1:
The patent applies dimensionality change by transitioning from a two-dimensional preliminary shape to a three-dimensional final shape through bending at the connecting portion. This allows the first and second terminal portions to be arranged in different spatial planes, enabling tab portions to interlock vertically while eliminating material waste that would otherwise occur in a flat configuration.
Solution Approach 2:
The patent implements nesting by having the second tab portions fit into gaps between adjacent first tab portions, and vice versa. This interlocking arrangement allows both terminal portions to be accommodated in the terminal accommodating chamber of the housing without requiring additional material, as the tab portions nest together in a space-efficient manner.
2Ease of operation
If the conductor plate is punched to create tab portions with gaps between them, then the tab portions can be accommodated in the terminal accommodating chamber, but the conductor plate material between the tab portions is discarded reducing manufacturing yield
Solution Approach 1:
By bending the preformed body at the connecting portion to create a three-dimensional structure, the patent enables the terminal portions to be vertically stacked rather than horizontally arranged. This dimensional change allows the gaps between tab portions to be utilized in the vertical dimension rather than requiring additional horizontal space, eliminating material waste.
Solution Approach 2:
Instead of arranging tab portions in a flat configuration where material between tabs is wasted, the patent inverts the arrangement by stacking terminal portions vertically. The gaps between tab portions in one terminal portion are utilized to accommodate tab portions from the other terminal portion, converting what would be wasted space into useful structural arrangement.
3Shape
If the first terminal portion and second terminal portion are arranged to be fitted to each other in the preliminary shape, then the three-dimensional arrangement can be achieved after bending, but the arrangement complexity increases
Solution Approach 1:
The patent divides the terminal fitting into distinct segments: first terminal portion, second terminal portion, and connecting portion. Each segment is designed with specific functions and can be independently arranged in the preliminary shape, simplifying the overall design process while enabling complex three-dimensional configuration after bending.
Solution Approach 2:
The patent implements preliminary action by arranging the first and second terminal portions in a fitted configuration in the preliminary flat shape, with tab portions positioned to interlock. This preliminary arrangement simplifies the subsequent bending process, as the three-dimensional configuration is essentially pre-planned in the two-dimensional layout, reducing the complexity of the final assembly.
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 reduces material waste by utilizing the entire conductor plate, thereby improving material yield and enhancing workability during assembly with a housing.
Implementation Method 1
the terminal fitting having a preliminary shape, being flat plate-shape, is bent at the connecting portion
Data Source
AI summary
A terminal fitting comprising: a first terminal portion in which first tab portions, extending from a first tab continuous connecting portion, are arranged; a second terminal portion in which second tab portions, extending from a second tab continuous connecting portion, are arranged; a connecting portion connecting the first and second terminal portions; and a contact portion to be connected to an external terminal. The terminal fitting has a three-dimensional shape in which the terminal fitting having a preliminary shape is bent at the connecting portion. In the three-dimensional shape, the first terminal portion and the second terminal portion are three-dimensionally arranged to be connected at the connecting portion. In the preliminary shape, the first terminal portion and the second terminal portion are arranged to be fitted to each other, and the first tab continuous connecting portion and the second tab continuous connecting portion are connected at the connecting portion.