Connector Terminal Recess Structure for Error-Proof Insertion
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Solution Overview
Problem
Existing connectors face challenges in preventing erroneous insertion of terminal fittings and maintaining strength, as notches in terminal fittings can cause stress concentration and incorrect insertion postures lead to physical disconnection.
Innovation Solution
A connector design featuring a terminal fitting with a tubular section bent in a tubular shape and a recess formed by cutting corner portions of the distal end, paired with a housing having a projection that inserts into the recess at the accommodation completion position, ensuring correct insertion and preventing erroneous insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a protrusion is provided in the terminal fitting to suppress erroneous insertion, then insertion accuracy is improved, but the housing size increases due to the required insertion track
Solution Approach 1:
The terminal connection section is designed with an asymmetric recess formed by cutting corner portions at the distal end, creating a unique geometric pattern that only fits with a corresponding asymmetric projection in the housing. This asymmetric configuration provides insertion guidance and prevents erroneous insertion without requiring additional protrusions or increasing housing size.
2Manufacturing precision
If a notch is provided in the terminal connection section to prevent erroneous insertion, then insertion accuracy is improved, but strength decreases due to stress concentration
Solution Approach 1:
The recess is formed by dividing the corner portions into multiple discrete cut portions rather than creating a single large notch. This segmentation approach reduces stress concentration at any single location while maintaining the overall recess structure for insertion guidance. The corner portions are cut separately to create the recess geometry without compromising structural integrity.
3Reliability
If the terminal fitting is designed to accommodate only in correct insertion posture, then connection reliability is improved, but device complexity increases due to additional insertion track requirements
Solution Approach 1:
The recess structure in the terminal connection section combines multiple functions into a single geometric feature: it provides insertion guidance, prevents erroneous insertion, and serves as a mechanical interlock with the housing projection. This merging of functions eliminates the need for separate insertion tracks or additional guiding structures, reducing overall device complexity while maintaining connection reliability.
Data Source
AI summary
A connector includes a terminal fitting that includes a terminal connection section, and a housing that includes a terminal accommodating section in which the terminal fitting is inserted into a terminal accommodating chamber in the terminal accommodating section in a terminal insertion direction and accommodated at an accommodation completion position, wherein the terminal connection section is a tubular section bent in a tubular shape with end surfaces of two end portions facing each other, and includes a recess that is recessed from a distal end of the terminal connection section on a terminal insertion direction side, in a terminal removal direction opposite to the terminal insertion direction, the terminal insertion direction being a tube axis direction.