Clean Body Electric Terminal High-Density Connectivity
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Solution Overview
Problem
Conventional miniature electric terminals are inadequate for accommodating the increasing number of electric connections in limited spaces within conventional vehicles, necessitating a more efficient design for high-density connectivity.
Innovation Solution
The electric terminal features a two-piece construction with a contact portion and a spring portion, including a contact box and spring boxes with arms that engage the contact arms to enhance contact force and maintain terminal shape, while being designed to fit seamlessly with a mat seal without damaging it, allowing for increased density without compromising space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional miniature electric terminals are used to increase the number of electric connections, then connectivity density improves, but the available space in limited vehicle areas is insufficient
Solution Approach 1:
The patent utilizes three-dimensional space more efficiently by designing the terminal body with vertical stacking of contact arms and spring boxes. The terminal extends in multiple dimensions rather than just horizontal plane, allowing more connections per unit area by exploiting the Z-axis dimension for contact arm arrangement and spring box positioning.
Solution Approach 2:
The spring boxes are positioned within or adjacent to the terminal body structure, with spring arms nested between contact arms. The guard structure is integrated into the terminal body, creating a compact nested arrangement where multiple functional elements occupy overlapping spatial volumes, maximizing space utilization.
2Reliability
If contact force is increased to ensure reliable electrical connection, then connection reliability improves, but the terminal structure becomes more complex
Solution Approach 1:
The patent combines the spring box structure with the terminal body, integrating the spring mechanism directly into the terminal housing rather than using separate external spring components. The guard structure is also merged with the terminal body, creating a unified structure that provides both mechanical support and contact force application without requiring additional independent components.
Solution Approach 2:
The terminal body serves multiple functions simultaneously: it provides structural support, houses the spring boxes, positions the contact arms, and includes integrated guard structures. This multi-functional design achieves reliable contact force application without proportionally increasing structural complexity, as single elements perform multiple roles.
3Quantity of substance
If terminal density is increased to fit more connections in limited space, then connectivity improves, but the risk of damaging sealing materials increases
Solution Approach 1:
The patent introduces a guard structure as an intermediary element between the spring box and the mat seal. This guard acts as a protective mediator that prevents direct contact between the rigid spring box corners and the flexible sealing material, distributing and reducing the mechanical stress on the seal while allowing the high-density terminal arrangement to be maintained.
4Area of stationary object
If spring box size is reduced to increase terminal density, then space efficiency improves, but the contact force may be insufficient
Solution Approach 1:
The patent positions the spring boxes at specific locations within the terminal body where they can effectively engage contact arms, rather than uniformly distributing spring boxes throughout the structure. The spring arms are positioned to engage specific sections of contact arms where the mechanical advantage is optimized, providing sufficient contact force with minimized spring box dimensions.
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 enables a higher number of electric connections in a smaller space, ensuring reliable contact force and preventing damage to sealing materials, thus addressing the need for improved connectivity in vehicles with numerous electric components.
Implementation Method 1
The spring portion includes a first spring arm that extends from the first spring box and engages the first contact arm
Data Source
AI summary
An electric terminal includes a contact portion that includes a contact box. A first contact arm extends from the contact box and is adapted to engage a corresponding terminal. The electric terminal also includes a spring portion with a first spring box that is located around a portion of the contact box. The spring portion also includes a second spring box that is located adjacent to the first spring box. The first spring box includes a first spring arm that engages the first contact arm. The second spring box includes a first guard that engages the first spring arm.