Connector Terminal Retention Using Welded Radial Protrusions
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Solution Overview
Problem
Existing connectors with integrated terminal housings and spring contact points face challenges in reducing terminal size and increasing manufacturing costs due to the need for separate terminal protrusions.
Innovation Solution
A connector design featuring a solid cylindrical electric wire connection portion with protruding pieces formed during thermal pressure welding, which are used to secure the terminal within a housing, reducing the need for separate protrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a terminal housing and spring contact point have an integrated structure, then the connector structure is simplified, but the terminal protruding portion cannot be disposed directly below the spring contact point and the terminal size increases
Solution Approach 1:
The terminal is divided into separate components: the terminal body and the terminal protruding portion. The terminal protruding portion is formed as a separate feature on the terminal body, allowing it to be positioned directly below the spring contact point without increasing overall terminal size. This segmentation enables precise positioning while maintaining compact dimensions.
2Reliability
If a terminal protruding portion is formed on the terminal, then the terminal can be locked to the housing, but the manufacturing cost of the terminal increases
Solution Approach 1:
The terminal protruding portion is integrated into the terminal body through a unified manufacturing process (thermal pressure welding). The protruding portion is formed simultaneously with the terminal connection portion, eliminating the need for separate manufacturing steps and reducing overall manufacturing cost while maintaining reliable locking functionality.
3Reliability
If the terminal protruding portion is disposed directly below the spring contact point, then the electrical connection is improved, but the terminal size increases
Solution Approach 1:
The terminal protruding portion utilizes the radial dimension of the terminal rather than extending axially. By forming the protruding portion in the radial direction from the terminal connection portion, the electrical connection point can be positioned directly below the spring contact point without increasing the terminal's axial length, thereby maintaining compact dimensions while improving electrical connection 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
This design allows for a reduced terminal size and lower manufacturing costs by eliminating the need for separate protrusions and simplifying the manufacturing process.
Implementation Method 1
a joining portion between an end surface of the electric wire connection portion and an end surface of the electric wire includes a protruding piece protruding in a radial direction of the electric wire connection portion
Data Source
AI summary
A connector includes a terminal, an electric wire, and a housing having a tubular portion that accommodates the terminal and the electric wire therein. An electric wire connection portion and a terminal connection portion are provided on both end sides of the terminal. The electric wire connection portion is connected to the electric wire. A joining portion between an end surface of the electric wire connection portion and an end surface of the electric wire includes a protruding piece protruding in a radial direction of the electric wire connection portion. A first retaining piece and a second retaining piece configured to be locked to the protruding piece are provided on an inner peripheral surface of the tubular portion. The second retaining piece is disposed at a position shifted from the first retaining piece in both a circumferential direction and an axial direction of the tubular portion.