Connector Terminal Segmentation for Miniaturized Vehicle Electronics
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Solution Overview
Problem
Vehicle-mounted electronic devices require miniaturization, but reducing the size of connectors and harnesses leads to incompatibility issues due to reduced spacing between connector terminals, which limits the guiding allowance and positional deviation absorption in movable connectors.
Innovation Solution
The electronic component features terminals with distinct connector-connection and external connection portions, where the clearance between adjacent connector-connection portions is larger than between external connection portions, allowing for size reduction while maintaining sufficient guiding allowance and positional deviation absorption through bent portions and a retention housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of the harness and harness connector are reduced to make the electronic device smaller, then the size of the electronic device is reduced, but the spacing between adjacent connector terminals becomes incompatible with the spacing of connection chambers, causing connector terminals to contact the housing and preventing proper insertion
Solution Approach 1:
The terminal is divided into two distinct portions: a first portion (connector-connection portion) that interfaces with the connection chamber, and a second portion (external connection portion) that connects to the harness connector. This segmentation allows each portion to have different spacing characteristics, enabling the terminal to bridge the spacing mismatch between the reduced-size harness connector and the connection chamber.
Solution Approach 2:
Different portions of the terminal are given different spatial configurations. The first portion has a larger clearance designed to match the connection chamber spacing, while the second portion has a smaller clearance matching the harness connector spacing. This local differentiation in spacing characteristics allows the terminal to accommodate both connection interfaces simultaneously.
2Manufacturing precision
If the size of the substrate connector is reduced to match the narrow spacing of connector terminals, then the spacing compatibility is improved, but the guiding allowance of the guide surfaces is reduced, limiting the ability to absorb positional deviation during insertion
Solution Approach 1:
The terminal structure separates the guiding function (first portion with larger clearance) from the connection function (second portion with smaller clearance). The first portion serves as the guiding element that enters the connection chamber with adequate clearance for positional adjustment, while the second portion provides the actual electrical connection at the harness interface.
Solution Approach 2:
The first portion of the terminal acts as an intermediary guiding element between the external connection portion and the connection chamber. It provides the necessary guiding allowance and positional deviation absorption, mediating the connection between the downsized harness connector and the connection chamber without requiring the connection chamber itself to be enlarged.
3Reliability
If the movable spring is used to absorb positional deviation and vibrations, then the connection reliability is improved, but the allowable error absorption is limited when the connector size is reduced
Solution Approach 1:
The guiding surfaces and larger clearance of the first portion perform the preliminary action of guiding and positioning the terminal before the movable spring engages. This preliminary guiding reduces the burden on the movable spring, allowing it to focus on absorbing residual positional deviations and vibrations, thereby extending the overall allowable error absorption capacity.
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 configuration enables reliable connection and size reduction of electronic components while maintaining effective guiding and positional deviation absorption, ensuring compatibility with downsized connectors and preventing terminal damage during insertion and extraction.
Implementation Method 1
a terminal having, for example, an inverted U-shape movable spring that displaceably supports the movable housing
Implementation Method 2
an inverted U-shape movable spring that displaceably supports the movable housing
Implementation Method 3
The guide surfaces are formed as a conical shape for guiding insertion of the connector terminal (11b) into the connection chamber
Data Source
AI summary
The size of an electronic component is made reducible so as to match a downsized connection object. The electronic component includes a first pin terminals, a second pin terminals, and an external connection case having a retention wall for retaining the first pin terminals and the second pin terminals. The first pin terminals and the second pin terminals have connector-connection portions and external connection portions, respectively. Clearances between adjacent connector-connection portions are made larger than corresponding clearances between adjacent external connection portions.