Combined Terminal Manufacturing via Window-Guided Link Cutting
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Solution Overview
Problem
Conventional methods for manufacturing combined terminals face challenges in securing positioning accuracy and increasing the number of processes due to separate supply and assembly of male and female terminals, which affects the integration and accommodation into connector housings.
Innovation Solution
A method involving the manufacture of first and second terminals on frames, where the second terminal has a window portion allowing for precise cutting of the link portion through it, enabling secure integration by crimping and positioning, thus reducing the risk of burrs and process complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If male and female terminals are separately supplied and assembled, then flexibility in manufacturing is improved, but positioning accuracy deteriorates and the number of processes increases
Solution Approach 1:
A positioning pin is introduced as an intermediary component between the male and female terminals. The positioning pin fits into a through-hole in the female terminal and engages with a positioning projection on the male terminal, ensuring precise alignment and positioning accuracy during assembly while maintaining the flexibility of separate manufacturing processes
2Stability of the object's composition
If link portions are cut after assembly, then integration is improved, but burrs may interfere with connector housing accommodation
Solution Approach 1:
The link portion is pre-cut through the window portion of the male terminal before final assembly. This preliminary cutting action removes the link portion while the terminals are still on the frame, preventing burrs from interfering with connector housing accommodation while maintaining integration. The window portion serves as a guide and protection during this cutting process
3Reliability
If multiple processes are used for terminal combination, then connection security is improved, but process complexity increases
Solution Approach 1:
Multiple functions are merged into single operations. The window portion in the male terminal serves multiple purposes: it guides the cutting blade for link portion removal, protects against burr formation, and ensures proper positioning during assembly. The positioning pin and projection system combines alignment and securing functions in a single integrated mechanism, reducing overall process complexity while maintaining connection security
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 method ensures accurate and secure integration of female and male terminals with reduced process steps, preventing burrs from interfering with connector housing accommodation and maintaining secure, integral connections.
Implementation Method 1
the pair of the crimping pieces 13, 13 is inwardly bent onto the crimped portion 121a and the crimped portion 121a is crimped
Implementation Method 2
by pressing (hammering) the male terminal 120, an expanded portion (not shown) is formed in the tip-end of the projection portion 125 already inserted in the through hole 15. Accordingly, the expanded portion and the plate portion 121 fasten the plate portion 12 of the female terminal 10 by sandwich manner
Data Source
AI summary
A combined terminal is made by combination of first and second terminals. The first terminal has a first plate portion. The second terminal has a second plate portion and a window portion formed in the second plate portion. The first and second terminals are combined so that the first and second plate portions are superposed while the first terminal remains to be linked to a frame by a link portion therebetween. The combined first and second terminals are removed from the frame by cutting the link portion through the window portion.