Conductive Terminal with Deflectable Beams for Thin Wire Connection
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Solution Overview
Problem
Existing electrical terminal devices require separate male and female terminals, which can be bulky and costly, especially in miniaturized applications, and struggle to securely connect thin wires with adequate mechanical robustness and conductivity.
Innovation Solution
The design of an electrical terminal device featuring an insulation displacement connector with a terminal section comprising deflectable beams made of conductive material, such as copper clad stainless steel, that securely holds a wire conductor without the need for a separate male terminal, utilizing an intermediate section for alignment and providing improved mechanical strength and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate male and female terminals are used, then electrical connection is achieved, but device size and cost increase
Solution Approach 1:
The patent combines the male and female terminal functions into a single integrated terminal device. The terminal includes both an insulation displacement connector section for receiving one wire and a terminal section with deflectable beams for receiving another wire, eliminating the need for separate male and female terminals while maintaining reliable electrical connection between wires
2Reliability
If separate male and female terminals are used, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The terminal device integrates multiple functions (insulation displacement connector and terminal section with deflectable beams) into a single component that can be manufactured as one piece from conductive material such as copper clad stainless steel, reducing the number of parts and assembly steps required, thereby lowering manufacturing cost
3Reliability
If thin wires are connected with conventional terminals, then electrical connection is made, but mechanical robustness is insufficient
Solution Approach 1:
The terminal device is made from copper clad stainless steel, which combines the high electrical conductivity of copper with the high mechanical strength and corrosion resistance of stainless steel. This composite material structure provides both excellent electrical connection for thin wires and sufficient mechanical robustness to secure them reliably
4Reliability
If conventional terminals are used, then electrical connection is achieved, but device complexity increases
Solution Approach 1:
The patent integrates the insulation displacement connector section and the terminal section with deflectable beams into a single terminal device, reducing the number of separate components. The intermediate section connects these two functional sections, creating a unified structure that simplifies the overall device complexity while maintaining reliable electrical connection capabilities
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 solution enables a compact, cost-effective, and reliable electrical connection for thin wires, eliminating the need for a male terminal and enhancing mechanical robustness while maintaining conductivity, suitable for ultra-small applications like hybrid and electric vehicles.
Implementation Method 1
The at least one beam has a spring memory urging the distal end of the at least one beam toward the first position so that the at least two beams cooperate to hold the second wire
Data Source
AI summary
An electrical terminal device includes an insulation displacement connector section and a terminal section. The insulation displacement connector section has a connector slot formed therein which is configured to receive a first wire conductor. The terminal section is connected to the insulation displacement connector section and includes at least two beams configured to receive a second wire conductor. A distal end of at least one beam is displaced from a first position to a second position upon receipt by the at least two beams of the second wire. The at least one beam has a spring memory urging the distal end thereof toward the first position so that the at least two beams cooperate to hold the second wire. The insulation displacement connector section and the terminal section are made of a conductive material to provide an electrical connection between the first and second wires.