Wire-to-board connector lock spring strip engagement
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Solution Overview
Problem
Existing wire-to-board connectors fail to maintain the fitted state when a pull-out force is applied to the electric wire, leading to disengagement.
Innovation Solution
A wire-to-board connector design featuring a metal first terminal attached to an electric wire and a metal second terminal mounted on a substrate, with a tubular accommodating section and an insertion section that includes a lock spring strip with a claw section, a lock hole, and an engaging surface, along with a shape retaining mechanism and improper insertion prevention protrusions, to securely connect the wire to the substrate and prevent disengagement under pull-out force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple fast-on tab terminal structure is used, then the device complexity is reduced and ease of manufacture is improved, but the connector reliability deteriorates when pull-out force is applied
Solution Approach 1:
The connector is divided into distinct functional components: a tubular accommodating section formed from a metal plate with bottom, side, and top plates; an insertion section with a lock spring strip; and engaging features including a claw section and engaging surface. This segmentation allows each component to be optimized for its specific function while maintaining overall simplicity in manufacturing.
Solution Approach 2:
The lock spring strip is designed as a dynamic element that can elastically deform during insertion and maintain continuous contact pressure on the engaging surface. The spring strip bends as the claw section engages with the engaging surface, creating a mechanical interlock that resists pull-out forces while allowing for assembly tolerance compensation.
2Device complexity
If a tubular accommodating section is formed by bending a metal plate, then the device complexity is reduced, but the shape stability deteriorates under insertion force
Solution Approach 1:
A shape retaining mechanism is pre-formed at the joint between the bottom plate and side plate before insertion occurs. This mechanism includes a protrusion on one plate that fits into a corresponding recess on the other plate, creating a predetermined reinforcement structure that maintains the tubular shape during the insertion process and prevents collapse.
3Reliability
If a lock spring strip with claw section is added to the insertion section, then the connector reliability is improved, but the device complexity increases
Solution Approach 1:
The lock spring strip is integrated directly into the insertion section as a single continuous piece, merging the locking function with the insertion structure. The spring strip extends from the insertion section body and forms the claw section that engages with the engaging surface, eliminating the need for separate locking components and reducing overall device complexity while maintaining reliability.
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 connector effectively maintains the fitted state even when a pull-out force is applied to the electric wire, ensuring reliable electrical connection and preventing disengagement.
Implementation Method 1
the insertion section includes a lock spring strip, claw section formed at a tip of the lock spring strip
Implementation Method 2
a shape retaining mechanism is formed in a joint between the bottom plate and one of the side plates for retaining the tubular shape of the accommodating section wherein the shape retaining mechanism is implemented by accommodating a shape retaining protrusion formed on the bottom plate in a shape retaining hole formed on one of the side plates
Data Source
AI summary
A wire-to-board connector 1 includes a plug 3 attached to an electric wire 2 and a receptacle 5 mounted on the surface of a substrate 4. Each of the plug 3 and the receptacle 5 is formed by bending a metal plate. The electric wire 2 is electrically connected to the substrate 4 by fitting the plug 3 with the receptacle 5. The receptacle 5 includes an accommodating section 6 formed in a tubular shape. The plug 3 includes an insertion section 31 to be inserted into the accommodating section 6. The insertion section 31 is provided with a claw section 38 and the accommodating section 6 is provided with an engaging surface 16. By inserting the insertion section 31 into the accommodating section 6, the claw section 38 is engaged with the engaging surface 16 and the plug 3 is thereby fitted with the receptacle 5. The claw section 38 and the engaging surface 16 are configured so as to prevent a pull-out force F acted on the electric wire 2 from acting to disengage the engaged state between the claw section 38 and the engaging surface 16.