Connector With Intermediate Terminal For Single Fastening
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Solution Overview
Problem
Existing shield connectors for devices lack visibility in confirming the connection between the tip side terminal and the base-end side terminal, leading to increased components and housing size due to the need for two bolting positions, which complicates the fastening process and may result in higher contact resistance.
Innovation Solution
A connector design featuring a metal intermediate terminal positioned between the terminal and the mating terminal, allowing for collective fastening with reduced components and visibility through a single fastening position, utilizing a hollow cylindrical intermediate terminal with a flange portion for support and tolerance absorption, and strategically placed clearances to prevent interference during fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two bolting positions are used to connect the connecting piece and the mating terminal, then the connection reliability is improved, but the number of fastening components increases and the housing size becomes larger
Solution Approach 1:
The patent combines two separate bolting operations into a single bolting operation by designing the intermediate terminal with a through-hole that allows one bolt to pass through all three components (connecting piece, intermediate terminal, and mating terminal). This merging of fastening operations reduces the number of fastening components from two bolts and two nuts to one bolt and one nut, while maintaining reliable electrical connection between all components
2Reliability
If two bolting positions are provided, then the connection reliability is improved, but the work opening becomes larger
Solution Approach 1:
The patent merges two separate tool spaces into a single tool space by positioning the bolt and nut for the single fastening operation at one location on the housing. This eliminates the need for two separate tool spaces, thereby reducing the work opening size while still achieving reliable connection through the intermediate terminal's through-hole design
3Strength
If the intermediate terminal has a larger cross-sectional area, then the rigidity is improved, but the conductor resistance increases
Solution Approach 1:
The patent uses a composite construction for the intermediate terminal, combining a metal collar (providing rigidity and mechanical strength) with a conductive material (providing low electrical resistance). The metal collar serves as both a structural support and an electrical conductor, while the conductive material filling the collar cavity enhances electrical conductivity without significantly increasing the terminal's outer dimensions
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 design reduces the number of fastening components and operations, minimizes contact resistance, and suppresses heat generation by ensuring reliable connections while maintaining a compact housing size, suitable for high-current applications.
Implementation Method 1
The terminal and the mating terminal are connected via the intermediate terminal by being collectively fastened by the fastening component and the fastened component
Implementation Method 2
The intermediate terminal is required to have sufficient rigidity to not be deformed by the fastening of the fastening component and the fastened component and has a larger cross-sectional area than the terminal and the mating terminal
Data Source
AI summary
A connector 10 disclosed by this specification is a connector 10 to be mounted on a casing 1 of a device by being inserted into a mounting hole 2 provided in the casing 1 and includes a terminal 40 connected to a wire W, a housing 20 having the terminal 40 mounted therein, and an intermediate terminal 30 made of metal, mounted in the housing 20 and disposed between the terminal 40 and a mating terminal 4 in the casing 1. A fastened component (nut 5) disposed in the casing 1 and to be fastened to a fastening component (bolt B), the mating terminal 4, the intermediate terminal 30 and the terminal 40 are arranged side by side in a fastening direction, and the terminal 40 and the mating terminal 4 are connected via the intermediate terminal 30 by being collectively fastened by the fastening component and the fastened component.