Connector Terminal Resin Positioning for Connectivity
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Solution Overview
Problem
The molding of synthetic resin on the outer peripheral surface of a connector main body can cause resin to flow into the body portion, leading to reduced connectivity due to leakage into the contact terminal portion and contact holding hole.
Innovation Solution
A connector terminal with a resin positioning portion that includes a guide wall with a tubular shape and a positioning wall formed by cutting and raising parts of the terminal main body, which includes a locking protrusion to restrict the position of the positioning wall relative to the guide wall, preventing resin from flowing into the contact portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a synthetic resin material is molded on the outer peripheral surface of the connector main body, then the connector main body is protected and formed, but the synthetic resin material flows into the body portion through cutouts and reduces connectivity
Solution Approach 1:
The body portion is divided into a resin-filled portion (where resin flows) and a non-resin-filled portion (contact terminal portion), separated by the positioning wall portion. This segmentation prevents resin from reaching the contact terminal portion while allowing complete molding of the connector main body, thus maintaining connectivity while enabling easy manufacturing through molding.
Solution Approach 2:
The positioning wall portion is formed by cutting and raising the metal plate before the resin molding process. This preliminary action creates a barrier that guides and restricts resin flow in advance, preventing resin from entering the contact terminal portion and contact holding hole, thereby ensuring connectivity is maintained throughout the molding process.
2Ease of operation
If lances are formed by cutting and raising side surfaces of the body portion, then positioning function is provided, but cutouts are created that allow resin to flow into the contact terminal portion
Solution Approach 1:
The body portion is segmented into resin-filled and non-resin-filled regions by the positioning wall portion. This segmentation allows the lances to maintain their positioning function (protruding from the body) while the positioning wall blocks resin flow paths, preventing resin from reaching the contact terminal portion despite the presence of cutouts.
Solution Approach 2:
The positioning wall portion acts as an intermediary barrier between the resin-filled portion and the contact terminal portion. It is formed by the same cutting and raising process that creates the lances, and it mediates the resin flow by redirecting it away from the contact terminal portion, thus preserving connectivity while maintaining the positioning function.
3Ease of manufacture
If the body portion is formed by punching and bending a metal plate, then the connector main body structure is created, but resin can leak through cutouts into the contact holding hole
Solution Approach 1:
The positioning wall portion is created as a preliminary structure during the metal plate forming process (punching and bending). This preliminary action establishes resin flow barriers before the resin molding occurs, preventing resin from leaking through the cutouts into the contact holding hole and contact terminal portion, thus maintaining connectivity while enabling easy metal plate fabrication.
Solution Approach 2:
The metal plate body is segmented into regions with different resin accessibility. The positioning wall portion creates a clear division between where resin can flow (resin-filled portion) and where it cannot (contact terminal portion), allowing the body to be formed by standard punching and bending while preventing resin leakage that would compromise connectivity.
Data Source
AI summary
A connector terminal may include a terminal main body extending along a center line, a contact portion provided at a first end portion of the terminal body in an extension direction of the terminal body, a lance portion provided at a second end portion of the terminal body in the extension direction of the terminal body, a connecting portion disposed between the contact portion and the lance portion, and a resin positioning portion disposed between the contact portion and the connection portion. The resin positioning portion may include a guide wall portion with a tubular shape having a through hole and a positioning wall portion configured to close the through bole inside the guide wall portion in the extension direction of the center line. The positioning wall portion includes a locking protrusion portion and the guide wall portion includes a locking recess portion that locks the locking protrusion portion.