Bent Connector Tab Structure for Vibration-Stable Electrical Terminals
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Solution Overview
Problem
Existing electrical terminals for connecting magnetic wires to connectors, such as RAST 2.5 connectors, face challenges in ensuring both the integrity and durability of the terminal and a stable connection, especially in environments with strong vibrations.
Innovation Solution
The electrical terminal features a flat wire contact portion and a connector tab with at least two parallel surfaces separated by an empty space, allowing for increased contact area and stability. The connector tab is bended to form parallel surfaces, and the terminal is made from a CuNiSi alloy to prevent cracking or orange peeling during production and use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical terminal design is more elaborated to increase contact area with connector, then connection stability is improved, but the terminal produces crack or orange peeling during production or use
Solution Approach 1:
The patent applies local quality by creating parallel surfaces at a specific location (the connector tab insertion region) rather than elaborating the entire terminal structure. This localized design increase contact area where needed while maintaining terminal integrity elsewhere.
Solution Approach 2:
The patent transitions from a single-plane contact design to a multi-dimensional structure by creating parallel surfaces separated by empty space. This dimensional change increases contact area without requiring a more complex overall terminal design.
2Strength
If the electrical terminal design is too simple to assure integrity and durability, then terminal strength is improved, but contact area with connector is not enough extended
Solution Approach 1:
The patent uses dimensional change by creating parallel surfaces separated by empty space, effectively increasing contact area from a single plane to multiple planes without complicating the overall simple terminal structure.
3Stability of the object's composition
If the connector tab is inserted into connector in simple design, then terminal integrity is maintained, but terminal disconnects easily from connector under vibration
Solution Approach 1:
The patent applies local quality by modifying only the connector tab region with parallel surfaces, maintaining the simplicity and integrity of the overall terminal while locally enhancing connection stability against vibration.
Data Source
AI summary
An electrical terminal for connecting a magnetic wire to a connector includes a flat wire contact portion for electrically connecting and hosting the magnetic wire, and a connector tab for the insertion into the connector, for example a RAST 2.5 connector. The connector tab is bended so as to include at least two parallel surfaces opposite to one another, separated by an empty space.