Angled Grounding Terminal Reduces Mounting Torque
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Solution Overview
Problem
Conventional grounding terminals require two screws for mounting and terminating ground wires, leading to high material costs and potential damage due to bending of crimp barrels during wire insertion, and they do not allow direct current flow from the grounding surface to the wire with minimal load through the terminal.
Innovation Solution
A grounding terminal with angled side walls and curved transition portions that reduces the torque required for mounting hardware, allowing secure attachment without special tools and enabling direct current flow from the grounding surface to the wire, made from lower-cost materials like phosphor bronze.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional grounding terminals use two screws for mounting and terminating ground wires, then the grounding connection is secure, but the material cost increases and the device complexity increases
Solution Approach 1:
The patent combines the mounting function and wire termination function into a single integrated grounding terminal structure. The terminal body simultaneously receives mounting hardware for securing to the grounding surface and crimp barrels for terminating ground wires, eliminating the need for separate mounting components and reducing overall device complexity while maintaining secure grounding connections
Solution Approach 2:
The grounding terminal is designed with multi-functionality, serving both as a mounting interface (receiving screws or other mounting hardware) and as a wire termination interface (housing crimp barrels for ground wires). This universal design allows a single component to perform multiple functions that previously required separate elements, reducing material costs and simplifying the overall assembly
2Ease of manufacture
If conventional grounding terminals have crimp barrels extending from the outboard end of the ring terminal, then wire termination is achieved, but the crimp barrel can bend causing permanent damage during wire insertion or transportation
Solution Approach 1:
The patent nests the crimp barrels within the terminal body structure rather than having them extend outward. The crimp barrels are positioned inside the terminal housing, protected by the terminal body walls, which prevents bending damage during wire insertion and transportation while still allowing effective wire termination through the crimping action
Solution Approach 2:
The terminal body structure serves as a protective cushion for the crimp barrels before any damaging forces are applied. The walls of the terminal body pre-position and support the crimp barrels, preventing them from bending under external forces during handling, transportation, or installation, thereby ensuring crimp barrel integrity is maintained throughout the product lifecycle
3Reliability
If conventional grounding terminals require highly conductive material for the entire body length, then proper grounding current flow is ensured, but the material cost increases
Solution Approach 1:
The patent applies local quality by making only the critical current path portions of the terminal body highly conductive, rather than the entire terminal. The mounting surface contact area and the crimp barrel contact areas are designed with high conductivity to ensure proper grounding current flow, while other non-critical portions of the terminal body can use less expensive materials, reducing overall material cost while maintaining grounding reliability
Data Source
AI summary
An embodiment is directed to a grounding terminal for mounting on a grounding surface. The grounding terminal has a top wall having a first mounting opening and a bottom wall having a second mounting opening. The second mounting opening is in alignment with the first mounting opening to receive mounting hardware therethrough. A first side wall extends between the top wall and the bottom wall at angles other than 90 degrees. A second side wall extends between the top wall and the bottom wall at angles other than 90 degrees. As the mounting hardware is tightened, the shape and positioning of the side walls relative to the top wall and bottom wall reduces the amount of torque required to move the top wall toward the bottom wall to allow for the mounting hardware to be tightened without the need for special tooling.