Power Connector Terminals with Through Holes for Insert Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for fabricating electrical power connectors, such as riveted and one-piece metal contacts, face challenges like increased manufacturing costs, reduced product yield due to material hardening and terminal breakage during shaping, and terminal displacement, which affect the lifespan of the connectors.
Innovation Solution
The design incorporates conducting terminals with a plate-like mounting portion featuring through holes, allowing for bending without stress and secure embedding within an electrically insulative terminal block molded via insert molding, which prevents terminal damage and displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If repeated stamping is used to form one-piece metal contacts, then the desired shape can be achieved, but the metal material hardens and terminals may break during bending
Solution Approach 1:
The patent introduces through holes at predetermined locations on the plate-like mounting portion before bending operations. These through holes act as stress relief features that prevent hardening and cracking during subsequent bending and shaping operations, allowing the terminal to be formed into the desired shape without compromising strength
2Ease of manufacture
If riveting technique is used to connect metal contact parts, then the conducting terminal can be assembled, but the fabrication process becomes complicated and product yield rate decreases
Solution Approach 1:
The patent integrates the mounting portion directly with the contact portion in a one-piece construction, eliminating the need for separate riveting operations to assemble multiple components. This merging of parts simplifies the manufacturing process and reduces the complexity associated with multi-step assembly operations
Solution Approach 2:
The plate-like mounting portion is formed with through holes and bent into the desired shape in advance, before the insert molding process. This preliminary shaping eliminates the need for post-assembly bending operations and complex riveting procedures, streamlining the overall manufacturing process
3Reliability
If insert molding is used to mold terminal block on conducting terminals, then terminals can be fixed, but terminal displacement may still occur affecting product lifespan
Solution Approach 1:
The mounting portion is pre-formed with through holes at specific locations and bent into the desired configuration before the insert molding process. This preliminary preparation ensures that when molten plastic is injected, it flows into and fills the through holes, creating mechanical interlocking that prevents terminal displacement during product use and extends product lifespan
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 solution enhances the product yield rate by preventing terminal breakage during fabrication and ensures secure fixation, thereby prolonging the lifespan of the electrical power connectors.
Implementation Method 1
an electrically insulative terminal block directly molded on the conducting terminals by insert molding
Data Source
AI summary
An electrical power connector includes a plurality of conducting terminals and an electrically insulative terminal block directly molded on the conducting terminals by insert molding. Each conducting terminal has a mating contact portion suspending in a front mating receiving hole of the electrically insulative terminal block, a plate-like mounting portion bent into shape and partially embedded in the electrically insulative terminal block and partially extending out of the bottom side of the electrically insulative terminal block, one or multiple through holes cut through the plate-like mounting portion and embedded in the electrically insulative terminal block, and a bent portion located at the plate-like mounting portion and transversely extending across each through hole and embedded in the electrically insulative terminal block.