Electrical Connector Terminal Groove Width Segmentation
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Solution Overview
Problem
Conventional electrical connectors for flat conductive members face issues with flux flowing up, leading to terminal instability and potential electrical contact failures due to capillary action, especially when the wider portion is provided around the connecting portion.
Innovation Solution
The electrical connector features a housing with terminal holding grooves that have specific width configurations to control terminal shift in the thickness direction, preventing flux from flowing up by maintaining a stable terminal position through narrower and wider groove portions, thereby preventing capillary action and ensuring the upper arm portion's mobility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the terminal holding groove has a wider portion around the connecting portion to prevent flux from flowing up, then flux prevention is improved, but the terminal may shift in the thickness direction due to reduced constraint
Solution Approach 1:
The terminal holding groove is segmented into multiple portions with different width characteristics: a first groove portion with width equal to or less than the terminal thickness for positioning, a second groove portion with larger width for flux prevention, and a third groove portion with narrow width for stabilizing. This segmentation allows each portion to fulfill its specific function independently, resolving the contradiction between flux prevention and position stability.
Solution Approach 2:
Different portions of the terminal holding groove are given different local qualities in terms of width. The first groove portion has a narrow width for precise positioning, the second groove portion has a wider width for preventing flux from reaching the connecting portion, and the third groove portion has a narrow width for stabilizing the terminal. This local differentiation allows the groove to simultaneously achieve both flux prevention and terminal stability.
2Stability of the object's composition
If the terminal holding groove has a narrower width to control terminal shift, then terminal position stability is improved, but flux may flow up more easily due to reduced space
Solution Approach 1:
The terminal holding groove is divided into distinct segments where the first groove portion provides narrow width for positioning stability, while the second groove portion provides wider space for flux prevention. This segmentation allows the groove to simultaneously achieve both terminal stability and flux prevention by assigning different width characteristics to different functional zones.
Solution Approach 2:
The groove structure implements local quality differentiation by making the first groove portion narrow for stability and the second groove portion wider for flux prevention. This localized variation in width allows each portion to optimize its specific function without compromising the other.
3Ease of manufacture
If the terminal holding groove has uniform width to simplify manufacturing, then manufacturing complexity is reduced, but the groove cannot simultaneously optimize both terminal positioning and flux prevention
Solution Approach 1:
The terminal holding groove is segmented into multiple portions with different width characteristics optimized for specific functions. This segmentation, while increasing structural complexity, actually simplifies manufacturing by allowing each portion to be formed with its optimal dimensions independently, rather than requiring a complex uniform structure that cannot achieve both positioning and flux prevention functions.
Solution Approach 2:
The groove structure implements local quality differentiation with different width characteristics in different portions. This approach improves reliability by allowing each portion to be optimized for its specific function (positioning or flux prevention), while the segmented structure makes manufacturing more straightforward compared to attempting to create a uniform groove that must compromise between conflicting requirements.
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 configuration effectively prevents flux from flowing into the connector, maintains terminal stability, and ensures reliable electrical contact by controlling terminal shift and preventing flux from reaching the upper arm portion, thus maintaining the terminal's surface condition and preventing electrical contact failures.
Implementation Method 1
flux flows up in the narrower portion along the plate surface of the connecting portion situated in the narrower portion due to a capillary action
Implementation Method 2
there is the space wide enough to stop the capillary action, between the inner surface of the wider portion and the plate surface of the terminal
Implementation Method 3
the combining portion deforms elastically
Data Source
AI summary
An electrical connector for connecting a flat conductive member includes a housing made of an electrical insulating material and including a terminal holding groove, and a terminal held in the terminal holding groove for contacting with the flat conductive member. The terminal holding groove includes a first groove portion and a second groove portion. The groove portion has a first groove width, and the second groove portion has a second groove width smaller than the first groove width. The terminal includes an upper arm portion, a lower arm portion extending in parallel with the upper arm portion, and a combining portion combining the upper arm portion and the lower arm portion. The lower arm portion includes a connecting portion accommodated in the first groove portion and to be soldered to a circuit board. The upper arm portion includes a pressing portion for pressing the flat conductive member.