Cable Terminal Alignment and Conduction Mechanism
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Solution Overview
Problem
Existing cable terminals for high-tension ignition plugs face misalignment issues during insertion, leading to unstable conduction and difficulty in detaching the plug cap, especially when the constricted portion is deeply concaved, and the acicular portion can deviate during mounting, resulting in insufficient contact.
Innovation Solution
A cable terminal with a crimped portion, an extending piece, and a conductor contacting piece, where the extending piece abuts the plug cap to determine the insertion direction and applies pressure to the plug terminal, and the conductor contacting piece is sandwiched between the plug terminal and the cable core, ensuring reliable contact without a connector spring, allowing easy attachment and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a connector spring is provided on the cable terminal to prevent misalignment, then insertion direction alignment is improved, but the plug cap cannot be easily detached when the constricted portion is deeply concaved
Solution Approach 1:
The invention removes the connector spring from the cable terminal structure. Instead of using a spring mechanism to prevent misalignment, the patent relies on the geometric fit between the insertion portion and plug terminal, allowing the plug cap to be easily detached even when the constricted portion is deeply concaved, while still preventing insertion direction misalignment through proper structural design
Solution Approach 2:
Rather than using an active spring mechanism to enforce alignment, the invention inverts the approach by designing the insertion portion and plug terminal with complementary geometries that naturally guide alignment during insertion, eliminating the need for spring-based constraint mechanisms
2Reliability
If the acicular portion is thrust into the cable body from its end face to establish conduction, then conduction is established, but the insertion direction may deviate resulting in insufficient contact
Solution Approach 1:
The insertion portion is designed with a tapered shape that guides the cable terminal into proper alignment with the plug terminal before the acicular portion contacts the cable core. This preliminary geometric guidance ensures correct insertion direction is established before conduction contact occurs, preventing deviation and ensuring sufficient contact area
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 prevents insertion direction deviations, maintains stable conduction, and enhances workability by ensuring reliable contact between the plug terminal and cable terminal, even with deeply concaved constricted portions, and allows easy detachment of the plug cap.
Implementation Method 1
the plug cap being made of an elastic body
Implementation Method 2
the extending piece is provided with a springy press piece that projects to a plug terminal of the ignition plug inserted into the plug cap and contacts an end face of the plug terminal
Data Source
AI summary
A cable terminal includes: a crimped portion crimped to a cable body; an extending piece provided integrally with the crimped portion to extend forward in an insertion direction; and a conductor conducting piece provided integrally with the crimped portion to face an end face of the cable body. An end of the extending piece abuts on an inner surface of a plug cap made of an elastic body to determine a position in terms of the insertion direction. The extending piece is provided with a springy press piece that projects to a plug terminal of an ignition plug inserted into the plug cap and contacts an end face of the plug terminal. The conductor contacting piece is sandwiched between a portion of an outer circumference of the plug terminal and a core exposed from the end face of the cable body. The plug terminal is disposed to be in tight contact with the inner surface of the plug cap.