Connector Terminal Holding Portion Interference Design
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Solution Overview
Problem
Existing connectors with press-fit terminal fittings face challenges in achieving simultaneous improved connection reliability, positioning accuracy, and sufficient terminal holding force, as they either damage the touching parts or allow resin adhesion due to interference with the terminal holding portion.
Innovation Solution
The connector design features a terminal fitting with a wide rectangular cross-sectional shape, including side surfaces and a ceiling surface that interfere with corresponding non-touching parts of the terminal holding portion, ensuring strong interference for holding and positioning while keeping the touching parts free from damage and resin adhesion, using side walls, upper and lower interfering portions to enhance frictional resistance and prevent movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the terminal holding portion interferes with the touching part of the terminal fitting, then the terminal holding force is increased, but the connection reliability deteriorates due to damage and resin adhesion
Solution Approach 1:
The terminal holding portion is divided into distinct functional zones: side walls for holding force, and base/ceiling walls with interfering portions that contact only non-touching parts. This segmentation allows the holding function and connection function to be spatially separated, resolving the contradiction between holding force and connection reliability.
Solution Approach 2:
Different regions of the terminal holding portion are designed with different interference characteristics. The side walls provide strong interference for holding force, while the base wall and ceiling wall provide controlled interference only at non-touching parts, preserving the quality of touching parts for reliable connection.
2Reliability
If the terminal holding portion holds only the four corners of the terminal fitting, then the touching part is protected from damage, but the terminal holding force is insufficient and positioning accuracy deteriorates
Solution Approach 1:
The holding portion contacts the terminal fitting at multiple separated locations: four corners via side walls, and additional non-touching parts via base and ceiling interfering portions. This segmented contact distribution increases total holding force while preserving touching part integrity.
Solution Approach 2:
The interference extends from traditional corner-only contact to include vertical dimension contact at non-touching parts of the base and ceiling surfaces. This multi-dimensional contact arrangement increases holding force without compromising the horizontal touching parts.
3Force
If the terminal holding portion interferes over the entire periphery of the terminal fitting, then the terminal holding force is sufficient, but the touching part interferes with the terminal holding portion reducing connection reliability
Solution Approach 1:
The terminal holding portion is segmented into zones of high interference (side walls at corners, base and ceiling interfering portions at non-touching parts) and zones of no interference (touching parts). This selective segmentation achieves sufficient holding force while protecting connection reliability.
Solution Approach 2:
The interference characteristic is made local rather than uniform: strong interference at side walls and base/ceiling non-touching parts, zero interference at touching parts. This local differentiation resolves the contradiction between overall holding force and local connection quality.
4Force
If the terminal fitting is press-fit into the terminal holding portion, then the terminal holding force is increased, but the positioning accuracy and connection reliability cannot be simultaneously improved
Solution Approach 1:
The press-fit process engages multiple segmented contact points: four corners through side walls and additional non-touching parts through base and ceiling interfering portions. This segmented engagement distributes pressing forces evenly, improving positioning accuracy while maintaining high holding force.
Solution Approach 2:
The terminal holding portion employs asymmetric interference patterns: strong interference at side walls for holding, and controlled asymmetric interference at base and ceiling non-touching parts. This asymmetric design optimizes both positioning accuracy during press-fit and connection reliability after assembly.
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 improves connection reliability, increases terminal holding force, and enhances positioning accuracy by preventing damage and resin adhesion while maintaining strong interference for secure press-fitting.
Implementation Method 1
the terminal fitting is press-fit into the terminal holding portion and is held strongly held while being positioned by the interference of the side surfaces with the side walls, the non-touching part of the ceiling surface with the upper interfering portion and the non-touching part of the base surface with the lower interfering portion
Data Source
AI summary
A connector (10) has a terminal fitting (17) press-fit into a terminal holding portion (18). The terminal fitting (17) has a wide rectangular cross-sectional shape and includes a lower surface (17A), two side surfaces (17B) standing upward from the opposite lateral edges of the lower surface (17A) and an upper surface (17C) connecting the upper edges of the side surfaces (17B). The terminal holding portion (18) includes two side walls (18B) that interfere with the side surfaces (17B), a bottom wall (18A) formed with lower interfering portions (18E) that interfere with non-touching parts (17D) of the lower surface portion (17A) not to be held in contact with a mating terminal fitting (21) and a ceiling wall (18C) formed with upper interfering portions (18D) that interfere with non-touching parts (17D) of the upper surface (17C) not to be held in contact with the mating terminal fitting (21).