Electrical Connector Terminal Fitting for Stable Snap-Locked Alignment
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Solution Overview
Problem
Existing electrical connectors face issues with mechanical stability due to movable conductive terminals relative to the insulation body, primarily caused by clearance or transition fittings at the buckle, which affect the connector's mechanical properties and alignment accuracy.
Innovation Solution
The design incorporates a notch portion in the insulation body and an engagement member with a wing that snap-fits with a buckle protrusion, ensuring an interference fit between the conductive terminal and the insulation body, preventing relative movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a clearance fitting or transition fitting is used between the conductive terminal and insulation body, then the manufacturing process is simpler, but the mechanical stability and alignment accuracy deteriorate due to relative movement
Solution Approach 1:
The conductive terminal is divided into multiple sections: a first conductive section inserted into the insulation body, a second conductive section extending outward, and a connection section joining them. This segmentation allows each part to serve a specific function - the first section provides stable insertion, the connection section enables positioning, and the second section maintains electrical connection, thereby achieving mechanical stability without complex fitting processes
Solution Approach 2:
The connection section acts as an intermediary element between the first conductive section (inserted in insulation body) and the second conductive section (external terminal). This intermediary structure with its specific geometry (including inclined surfaces and positioning features) mediates the connection, enabling precise positioning and stable mechanical coupling without requiring high-precision clearance or transition fittings
2Manufacturing precision
If a clearance fitting is used at the buckle, then the manufacturing tolerance is more relaxed, but the alignment accuracy and mechanical properties deteriorate due to gaps
Solution Approach 1:
The connection section is designed with predetermined geometric features (inclined surfaces, positioning protrusions) that automatically guide and constrain the relative positioning of the conductive terminal and insulation body during assembly. This preliminary structural design pre-establishes the correct alignment, eliminating the need for high-precision machining tolerances and preventing gap formation at the buckle
Solution Approach 2:
The connection section employs asymmetric geometric features, including inclined surfaces at specific angles and non-symmetric positioning structures. These asymmetric elements create a unique fit that prevents relative movement and ensures precise alignment, while allowing for relaxed manufacturing tolerances in other dimensions
3Ease of operation
If the conductive terminal is made movable relative to the insulation body, then the ease of assembly is improved, but the mechanical properties and structural integrity deteriorate
Solution Approach 1:
The connection section incorporates dynamic geometric features, including inclined surfaces that allow for self-adjustment during assembly and elastic deformation capabilities. These dynamic elements enable easy insertion and assembly while automatically transitioning to a locked, stable position that provides strong mechanical coupling, thus achieving both ease of assembly and high mechanical strength
Data Source
AI summary
A connector includes an insulation body having a first side surface and a second side surface adjacent with each other at a corner, a buckle protrusion on the first side surface, and a notch portion at the corner. The connector includes a conductive terminal partially pressed against the second side surface of the insulation body and an engagement member having a main body and a wing. The main body is disposed on the second side surface. The wing extends from the main body in a first direction in which the main body faces the second side surface. The wing has a buckle opening interference fitted with the buckle protrusion. The engagement member presses the conductive terminal partially against the second side surface and the notch portion is covered by a portion of the engagement member between the main body and the wing.