Electric Connector Terminal Interface Assembly Method
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Solution Overview
Problem
The assembly of right-angle electric connectors is cumbersome due to the need to insert the wire end through a wire opening before crimping, which can be difficult and may result in improper alignment or damage to the connector.
Innovation Solution
A method involving an electric terminal with a termination offset that allows it to be initially inserted into a wire opening, then moved into a seated position over a cradle on the connector body, ensuring the wire is coaxial with the opening, facilitating easier assembly and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the wire end is inserted through the wire opening before crimping, then the connection between wire and terminal is achieved, but the assembly process becomes cumbersome and difficult
Solution Approach 1:
The terminal is pre-positioned in the connector body at the correct orientation and location before wire insertion. The terminal includes positioning features such as a rear wall and side walls that define the wire opening, ensuring the terminal is already in its final seated position. This preliminary positioning eliminates the need for complex alignment during assembly and simplifies the wire insertion process.
Solution Approach 2:
The terminal acts as an intermediary component between the connector body and the wire. It provides a structured interface with defined geometry (rear wall, side walls, cradle) that guides the wire into proper alignment and facilitates the crimping process. The terminal's design mediates the connection process by providing a predetermined path and positioning mechanism for the wire.
2Reliability
If the terminal is fixed inside the connector body, then proper mating and damage prevention are maintained, but the assembly process requires complex insertion steps
Solution Approach 1:
The terminal is pre-assembled into the connector body with its positioning features (rear wall, side walls) already in place. This preliminary fixation ensures the terminal cannot move or rotate during wire insertion, maintaining reliability while simplifying the overall assembly process. The terminal is prepared in advance to receive the wire in the correct orientation.
Solution Approach 2:
The connector assembly is divided into distinct functional segments: the connector body, the terminal, and the wire. Each segment has defined interfaces and positioning features that work together. The terminal is a separate component with specific geometric features that interface with both the connector body and the wire, allowing for modular assembly while ensuring proper alignment and stability.
3Strength
If the wire is tugged or pulled after crimping, then connection strength is tested, but the terminal may pull out of the connector body
Solution Approach 1:
The terminal has different geometric features at different locations to serve different functions: the rear wall and side walls provide retention and positioning within the connector body, while the cradle provides wire guidance and support. This local differentiation of structural properties ensures both strong wire connection and secure terminal retention against pull-out forces.
Solution Approach 2:
The terminal's rear wall and side walls are designed to engage with the connector body before any load is applied to the connection. This preliminary mechanical engagement creates a retention mechanism that prevents the terminal from pulling out if the wire is tugged or pulled, cushioning against potential failure modes before they occur.
Data Source
AI summary
A method of assembling an electrical connector includes inserting an electric terminal with an attached wire to an initially inserted position in a wire opening defined by a connector body. The electric terminal is moved through the wire opening in an insertion direction relative to the connector body. The electric terminal is attached to the connector body in a seated position, wherein the wire is coaxial with the wire opening.