Connector Terminal Sheath Structure for Reliable Locking Conductivity
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Solution Overview
Problem
Existing heavy-duty connectors face issues with thin radial flange wall thickness affecting conductivity and manufacturing difficulties due to the need for stamping, leading to complex structures, low efficiency, and high costs from separate elastic locking pieces and spring coils.
Innovation Solution
A connector terminal design featuring a hollow cylindrical terminal body with an integrated terminal sheath containing elastic locking pieces that tilt outward for locking, eliminating the need for a separate elastic locking piece and spring coil, thereby simplifying the structure and improving conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a radial flange is formed on the circumferential wall of the terminal body by stamping, then the elastic locking piece can be fixed to lock the terminal in the housing, but the wall thickness of the radial flange becomes thin, seriously affecting the conductivity of the terminal
Solution Approach 1:
The patent combines the terminal body and terminal sheath into an integrated structure where the terminal sheath is crimped onto the terminal body. The elastic locking piece is formed directly on the terminal sheath rather than requiring a separate radial flange on the terminal body, merging multiple functions into a unified structure that maintains conductivity while providing reliable locking.
Solution Approach 2:
The patent transitions from a two-dimensional radial flange stamped on the terminal body surface to a three-dimensional integrated terminal sheath structure that encompasses the terminal body. This dimensional change allows the elastic locking piece to be formed on the sheath without compromising the conductivity of the terminal body, as the sheath provides the necessary structural support.
2Reliability
If a circle of radial flange is stamped on the circumferential wall of the terminal body, then the elastic locking piece can be fixed, but it is easy to tear the circumferential wall of the terminal body, which increases the difficulty of terminal manufacturing
Solution Approach 1:
The patent merges the terminal body and terminal sheath into an integrated assembly where the sheath is crimped onto the body. The elastic locking piece is formed on the sheath rather than requiring stamping of a radial flange on the terminal body, eliminating the tearing issue while maintaining locking reliability and simplifying manufacturing.
Solution Approach 2:
The patent extracts the elastic locking piece formation from the terminal body stamping process and relocates it to the terminal sheath. This separation allows the terminal body to be manufactured without the complex radial flange stamping operation that causes tearing, while the sheath provides the necessary locking functionality.
3Force
If a spring coil is installed on the terminal to provide auxiliary contact force to the elastic cantilever, then the contact force is improved, but it is necessary to provide a separate elastic locking piece and spring coil, leading to complex structures, low manufacturing efficiency, and high costs
Solution Approach 1:
The patent combines the functions of the elastic locking piece and spring coil into a single integrated terminal sheath structure. The sheath itself provides the elastic cantilever that contacts the housing, eliminating the need for separate locking pieces and spring coils, thereby simplifying the structure while maintaining necessary contact force.
Solution Approach 2:
The terminal sheath is designed to perform multiple functions: it provides structural support, houses the elastic locking piece, and incorporates the spring coil functionality through its own elastic deformation. This multi-functionality reduces the number of separate components needed while maintaining the required contact force and locking 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 enhances manufacturing efficiency, reduces production costs, and ensures reliable electrical contact by integrating the elastic locking piece and auxiliary cantilevers within the terminal sheath, eliminating the need for a radial flange and separate spring coils.
Implementation Method 1
a terminal sheath (2) that is sheathed on the hollow cylindrical part (10) of the terminal body (1)
Implementation Method 2
The elastic locking piece (22) tilts outward and is configured to engage with a connector housing to lock the connector terminal in the connector housing
Data Source
AI summary
A connector terminal includes a terminal body having a hollow cylindrical part and a terminal sheath that is sheathed on the hollow cylindrical part of the terminal body. The terminal sheath has an elastic locking piece formed on a circumferential wall. The elastic locking piece tilts outward and is configured to engage with a connector housing to lock the connector terminal in the connector housing.