Chamfered Connector Terminal Structure for Stress Distribution

Solution Overview

Problem

Conventional connectors concentrate stress on terminal portions when coupled to a mating connector, leading to potential damage and inefficiencies.

Innovation Solution

A connector design featuring a resin body member supporting outer connection terminals with chamfered portions and specific orientations to distribute stress, reducing concentration on terminal ends.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional connectors use simple terminal structures, then manufacturing is easier, but stress concentration occurs on terminal portions during coupling

Engineering Contradiction:

Improveterminal structure simplicityVSAvoidstress distribution on terminals

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The terminal structure incorporates chamfered portions at specific locations (first, second, third, and fourth chamfered portions) to create local structural variations. These chamfered portions are positioned at the coupling ends to distribute stress during mating, while other portions of the terminal maintain simpler geometries for ease of manufacture. This local quality modification resolves the contradiction by adding complexity only where needed for stress distribution.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The chamfered portions introduce curved or angled surfaces at the terminal coupling ends, replacing sharp edges or flat surfaces. This curvature design allows for more gradual stress distribution during the coupling process, reducing stress concentration points while maintaining overall structural simplicity and manufacturability.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Manufacturing precision

If terminal portions have simple geometric shapes, then manufacturing precision is easier to achieve, but stress concentration damages terminals during coupling

Engineering Contradiction:

Improveterminal geometry accuracyVSAvoidterminal resistance to stress damage

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The terminal structure incorporates chamfered portions at specific locations (first, second, third, and fourth chamfered portions) to create local structural variations. These chamfered portions are positioned at the coupling ends to distribute stress during mating, while other portions of the terminal maintain simpler geometries for ease of manufacture. This local quality modification resolves the contradiction by adding complexity only where needed for stress distribution.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The chamfered portions act as pre-designed stress distribution features that are built into the terminal structure before coupling occurs. These features provide beforehand cushioning by creating gradual transition zones that prevent sudden stress concentration during the coupling process, thereby protecting the terminal from damage while maintaining manufacturing precision.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Productivity

If connectors are coupled frequently, then productivity increases, but stress concentration leads to terminal damage and reduced reliability

Engineering Contradiction:

Improvecoupling frequencyVSAvoidterminal durability under repeated stress

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The chamfered portions act as pre-designed stress distribution features that are built into the terminal structure before coupling occurs. These features provide beforehand cushioning by creating gradual transition zones that prevent sudden stress concentration during the coupling process, thereby protecting the terminal from damage while maintaining manufacturing precision.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The terminal structure modifies geometric parameters at critical locations by incorporating chamfered portions with specific angles and dimensions. This parameter change creates optimized stress distribution characteristics that enable the terminal to withstand repeated coupling operations, thereby supporting high productivity while maintaining reliability across multiple coupling cycles.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250379385A1Connector and connector set

Publication Date: 2025.12.11 MURATA MFG CO LTD

AI summary

A connector includes a resin body member and one or more first outer connection terminals supported by the resin body member. The one or more first outer connection terminals each include a main body portion including a first portion that extends in an up-down direction, a second portion, above the first portion, that extends in a left-right direction, a third portion, below the second portion, that extends in the up-down direction, a first coupling portion that is bent and physically connects an upper-end portion of the first portion and a left-end portion of the second portion to each other, and a second coupling portion that is bent and physically connects a right-end portion of the second portion and an upper-end portion of the third portion to each other. A second front or rear surface is connected to a first inner peripheral surface via one or more chamfered portions.