Connector Terminal Holding Structure for Electric Short-Circuit Prevention
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Solution Overview
Problem
Existing connector terminal holding structures face issues with electric short-circuits due to metal burrs and improper positioning when press-fitted into resin cases, as they often result in tilting or deviation of the terminals.
Innovation Solution
A connector terminal holding structure is designed with a terminal contact portion that does not contact the discharge hole, a press-fitted width portion that fits into the inner wall of the discharge hole, and an insertion position determination portion that restricts the insertion position, reducing the occurrence and dimension of metal burrs and ensuring proper positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If projecting portions are provided on the connector terminal to prevent metal burrs, then electric short-circuit prevention is improved, but the connector terminal may tilt or fail to reach proper position
Solution Approach 1:
The connector terminal is divided into three distinct portions: a terminal contact portion with smaller width that passes through the discharge hole, a press-fitted width portion with larger width that is press-fitted into the through-groove, and an insertion position determination portion that abuts on the inner wall. This segmentation allows each portion to perform its specific function without interfering with others, resolving the contradiction between burr prevention and positioning accuracy.
Solution Approach 2:
Different portions of the connector terminal are given different width characteristics tailored to their specific functions. The terminal contact portion has smaller width for passing through, the press-fitted width portion has larger width for secure fixation, and the insertion position determination portion has specific width for position control. This local differentiation resolves the contradiction by optimizing each region for its specific purpose.
2Manufacturing precision
If the press-fitted width portion is press-fitted into the inner wall of the discharge hole, then positioning accuracy is improved, but metal burrs may occur during insertion
Solution Approach 1:
The connector terminal is segmented into a terminal contact portion with smaller width and a press-fitted width portion with larger width. The smaller terminal contact portion leads the insertion process and passes through the discharge hole first, reducing the impact force and preventing metal burrs, while the larger press-fitted width portion is subsequently press-fitted into the through-groove for accurate positioning.
Solution Approach 2:
The terminal contact portion with smaller width performs the preliminary action of passing through the discharge hole before the press-fitted width portion is press-fitted into the through-groove. This preliminary passage reduces the insertion force required and prevents metal burrs from occurring during the press-fitting process.
3Ease of operation
If the terminal contact portion has smaller width to pass through the discharge hole, then insertion ease is improved, but the overall connector terminal width must be increased to maintain press-fitting effectiveness
Solution Approach 1:
The connector terminal is designed with local quality variations where the terminal contact portion has smaller width for easy insertion through the discharge hole, while the press-fitted width portion has larger width for effective press-fitting into the through-groove. This localized differentiation allows the terminal to achieve both insertion ease and press-fitting effectiveness without requiring an overall increase in dimensions.
Solution Approach 2:
The solution transitions from a uniform width design to a multi-dimensional width design where different portions of the connector terminal have different widths. This dimensional variation allows the terminal to pass through the discharge hole with smaller width while maintaining effective press-fitting width in the through-groove region.
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A connector terminal holding structure which holds a metallic connector terminal press-fitted into a resin case is provided. A connector terminal 31 includes a terminal contact portion 31a that has such a width as not to come in contact with a discharge hole 32f of a through-groove 32d provided in the resin case 32, a press-fitted width portion 31b that is connected to the terminal contact portion 31a and has such a width as to be press-fitted into the inner wall of the discharge hole 32f, and an insertion position determination portion 31c that determines an insertion position of the connector terminal 31. The connector terminal 31 is inserted into the through-groove 32d from the terminal contact portion 31a so as to be exposed from the discharge hole 32f, the insertion position of the connector terminal 31 is determined by the insertion position determination portion 31c, and only the vicinity of a leading end portion of the press-fitted width portion 31b is press-fitted into and held by the inner wall of the discharge hole 32f.