Connector Pressing Protrusion Vibration Suppression
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Solution Overview
Problem
Existing connectors experience terminal rattling and vibration due to vehicle vibrations, leading to unstable contact resistance and potential connection failures, especially when press-fit ribs wear down and cause friction issues.
Innovation Solution
The connector incorporates pressing protrusions on the terminal or front holder, which are elastically deformed by the fitting pressing force to securely hold the terminal in place, preventing rattling and inclining within the terminal accommodating chamber, and a temporary locking mechanism to facilitate easy mating terminal insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the terminal is accommodated in the terminal accommodating chamber with a clearance, then the terminal can be easily inserted and removed, but the terminal vibrates due to vehicle vibrations causing unstable contact resistance
Solution Approach 1:
The patent changes the physical state of the pressing protrusion from rigid to elastic by selecting appropriate elastic modulus values. This allows the pressing protrusion to deform elastically under vibration loads, maintaining constant contact pressure with the terminal while absorbing vibration energy, thus preventing terminal vibration and ensuring stable contact resistance
Solution Approach 2:
The pressing protrusion is designed with elastic properties beforehand to cushion against vibration shocks before they can cause terminal movement. The elastic deformation capability is built into the structure in advance, allowing it to absorb and dissipate vibration energy, preventing the terminal from rattling in the accommodating chamber
2Reliability
If a press-fit rib is provided to suppress terminal vibration, then the terminal is securely retained, but the metal terminal may shave the press-fitting rib causing connection failure
Solution Approach 1:
The patent changes the material parameter of the pressing protrusion from rigid metal to elastic material with specific elastic modulus range (0.03-0.08 N/mm²). This parameter change allows the pressing protrusion to deform elastically rather than rigidly, reducing mechanical wear and preventing the generation of wearing powder that would occur with rigid press-fit ribs
Solution Approach 2:
The pressing protrusion acts as an intermediary element between the terminal and the terminal accommodating chamber. Instead of direct metal-to-metal contact between the terminal and rigid press-fit rib, the elastic pressing protrusion mediates the interaction, distributing contact stresses and preventing direct shaving of the rib structure
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 suppresses terminal vibration and friction, enhancing connection reliability by ensuring stable contact and preventing wear-related failures, even in harsh environments like automobiles.
Implementation Method 1
the pressing protrusion is elastically deformed by a fitting pressing force acting on the front holder to press and urge the box-shaped portion of the terminal toward inside of the terminal accommodating chamber
Implementation Method 2
the terminal lock 517 is elastically restored by accommodating the terminal 501 at a predetermined position after being bent toward the outside of the terminal accommodating chamber 509, thereby locking the locking protrusion 520
Data Source
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AI summary
A connector includes a terminal-equipped electrical wire, an inner housing, an outer housing, and a front holder. The terminal-equipped electrical wire includes an electrical wire and a terminal, the terminal having a box-shaped portion configured to fit with a mating terminal in a fitting direction intersecting with an extending direction of the electrical wire. The inner housing includes a terminal accommodating chamber. The outer housing includes an electrical wire leading-out opening and a housing fitting opening. One or more pressing protrusions are provided on at least one of the terminal and the front holder. When the outer housing is fitted to the mating connector, the one or more pressing protrusions are elastically deformed by a fitting pressing force acting on the front holder to press and urge the box-shaped portion toward inside of the terminal accommodating chamber.