Conductive Terminal Structure for Flat Enameled Wire Piercing
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Solution Overview
Problem
Existing conductive terminals are not suitable for flat enameled wires due to insufficient piercing of the insulating layer, leading to high resistance and instability in electrical connections.
Innovation Solution
A conductive terminal design featuring a U-shaped structure with serrated blade elements and aligned openings, equipped with convex angular portions to pierce the insulating layer of flat enameled wires, ensuring stable electrical connections and reduced resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional conductive terminal is used for flat enameled wires, then the terminal structure is simple, but the insulating layer piercing is insufficient leading to high resistance
Solution Approach 1:
The blade elements are equipped with convex angular portions at specific locations to concentrate piercing force on the insulating layer, creating localized high-quality contact points that ensure reliable electrical connection without requiring complex overall terminal structure
Solution Approach 2:
The terminal structure is divided into multiple blade elements with convex angular portions, where each blade element independently pierces and clamps the wire. This segmentation allows the piercing function to be distributed across multiple simple components rather than one complex component
2Adaptability or versatility
If the conductive terminal uses a single opening design, then the device complexity is low, but it cannot adapt to various wire diameters
Solution Approach 1:
The terminal incorporates multiple openings of different sizes within a single blade element structure, allowing the same terminal to accommodate various wire diameters. This multi-functional design enables one terminal to serve multiple wire size requirements without requiring separate terminals for each diameter
3Reliability
If the insulating layer is not properly pierced, then the terminal structure remains simple, but contact resistance increases
Solution Approach 1:
The convex angular portions are pre-formed on the blade elements during terminal manufacturing, so that the piercing capability is built into the terminal structure before use. This preliminary preparation ensures effective insulating layer piercing during the connection process without requiring complex manual intervention or additional manufacturing steps
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
The design allows for efficient electrical connection with flat enameled wires, reducing contact resistance and enhancing connection stability, suitable for high-current applications, and adaptable to various wire diameters.
Implementation Method 1
The plurality of pairs of first convex angular portions are arranged along a direction of the first opening and pierce an insulating layer of a wire
Data Source
AI summary
A conductive terminal includes a body part, a first pair of blade elements extending from the body part and spaced apart from each other to form a first opening, a second pair of blade elements having a second opening aligned with and connected with the first opening, a size of the first opening is different than a size of the second opening, and a connecting element connecting the first pair of blade elements and the second pair of blade elements to form a U-shaped connection. The first pair of blade elements have a plurality of pairs of first convex angular portions. The plurality of pairs of first convex angular portions are arranged along a direction of the first opening and pierce an insulating layer of a wire so that the conductive terminal clamps the wire and an electrical connection is formed between the conductive terminal and the wire.