Connector Terminals with Bent Projecting Portions for Compact Wiring
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Solution Overview
Problem
Existing electrical connection assemblies in automotive vehicles face challenges in reducing width while preventing short circuits between terminals or conductors, as smaller intervals between terminals can lead to short circuits, limiting the ability to minimize the overall assembly width.
Innovation Solution
A connector design with terminals having a held portion and an outward projecting portion, featuring a first and second projecting portion, allows for conductive connection while maintaining intervals, preventing short circuits by arranging conductor connection surfaces at specific intervals and using a bent shape to avoid interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If terminals are arranged with smaller intervals to reduce assembly width, then the width of the electrical connection assembly is reduced, but short circuits may occur between adjacent terminals via solder
Solution Approach 1:
The conductor connection surface is positioned at a location separated from the terminal holding portion surface in the first direction (vertical dimension), rather than being coplanar with it. This dimensional separation allows terminals to be arranged closer together in the array direction while maintaining adequate isolation, as solder applied to the conductor connection surface will not bridge adjacent terminals on the terminal holding portion surface.
Solution Approach 2:
The terminal is divided into distinct functional portions: a held portion for mounting in the terminal holding portion, and a conductor connection surface for connecting to conductors. This segmentation allows the conductor connection surfaces of adjacent terminals to be positioned at locations that prevent solder bridging, while still maintaining compact overall terminal arrangement.
2Reliability
If terminals are arranged with larger intervals to prevent short circuits, then short circuit prevention is improved, but the width of the electrical connection assembly increases
Solution Approach 1:
By positioning the conductor connection surface in a location separated from the terminal holding portion surface in the first direction, the patent enables compact in-plane terminal spacing while maintaining adequate solder isolation. This vertical separation allows terminals to be arranged with smaller intervals in the array direction without increasing assembly width.
3Length of stationary object
If terminals are positioned close together to minimize assembly size, then assembly compactness is improved, but interference between adjacent terminals may occur
Solution Approach 1:
The conductor connection surface is positioned at a location separated from the terminal holding portion surface in the first direction. This vertical separation creates physical isolation between adjacent terminals, preventing solder and conductor interference even when terminals are densely packed in the array direction, thereby simplifying the overall device design.
Data Source
AI summary
An electrical connection assembly includes a connector (CN) and a wiring material with conductors. The connector (CN) includes terminals (20) and an insulating housing (30) having a terminal holding portion (32) for holding the wiring material (10) such that the conductors are connected to the respective terminals (20). Each terminal (20) includes a held portion (22) and an outward projecting portion (24) projecting out from a surface (32a) of the terminal holding portion (32). The outward projecting portion (24) includes a first projecting portion (26) projecting in a first direction and a second projecting portion (27) extending from the first projecting portion (26) in a second direction closer to a direction parallel to the surface of the terminal holding portion (32) than the first direction. An outer surface of the second projecting portion (27) has a conductor connection surface (27a) connectable to the conductor extending in the second direction.