Connector Terminal Layout Using External Box-Surface Contact

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Solution Overview

Problem

The existing connector designs limit the degree of freedom in designing the connection terminal due to the restricted inside shape of the box portion, which confines the placement and contact piece location.

Innovation Solution

A connector design that allows the contact portion of the mounting terminal to electrically connect with the outer surface of the tubular box portion, enabling a more flexible design without internal contact pieces, and includes a pair of sandwiching pieces for secure contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the box portion is designed with a specific internal shape to accommodate and position the branched terminal portion and contact piece, then reliable electrical connection is achieved, but the degree of freedom in designing the connection terminal is limited

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoiddesign freedom of connection terminal

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

Instead of having the contact piece inside the box portion contact the terminal from the inside (conventional approach), the invention inverts the arrangement by having the terminal contact the outer surface of the box portion from the outside. This inversion resolves the contradiction by enabling design freedom while maintaining reliable electrical connection through external contact.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If the contact piece is positioned inside the box portion to face the inserted terminal, then electrical connection is ensured, but the internal shape of the box portion becomes constrained

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidinternal shape of box portion

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The invention extracts the contact piece from the internal structure of the box portion and relocates it to the terminal itself. This extraction eliminates the constraint on the box portion's internal shape, allowing the box to have any desired form while the terminal's contact piece provides the necessary electrical connection function.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If the connection terminal includes internal contact pieces and specific internal shaping, then electrical connection functionality is achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By extracting the contact piece from the box portion's internal structure and placing it on the terminal, the invention simplifies manufacturing. The box portion can now be produced as a simple tubular structure without complex internal features, reducing mold complexity and manufacturing cost while maintaining electrical connection reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS20250385467A1connector

Publication Date: 2025.12.18 AUTONETWORKS TECH LTD

AI summary

It is aimed to provide a connector capable of improving a degree of freedom in designing a connection terminal. A connector (10) is provided with a housing (11), a connection terminal (12) to be arranged inside the housing (11) and a mounting terminal (13) to be mounted into the housing (11). The connection terminal (12) includes a tubular box portion (28). The mounting terminal (13) includes a contact portion (48) to be electrically connected to the connection terminal (12) by contacting an outer surface of the box portion (28).