Crimp Terminal Body Notch Structure to Prevent Corner Cracks
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Solution Overview
Problem
High-voltage connectors experience cracks at the corner between the side wing and connecting part of the terminal body during crimping, leading to changes in the insertion gap size, affecting the mating terminal's insertion.
Innovation Solution
A stress relief notch is formed at the corner between the side wing and connecting part of the terminal body to prevent local stress concentration, ensuring the terminal body remains intact and maintains proper insertion gap size during crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If an arc shaped chamfer is formed at the corner between the side wing and connecting part, then the terminal body structure is simplified, but stress concentration occurs during crimping leading to cracks
Solution Approach 1:
The patent applies local quality by creating a stress relief notch specifically at the corner position where stress concentration occurs during crimping. This localized structural modification targets the critical area without changing the overall terminal body design, allowing the chamfer to remain simple while the notch provides localized stress relief to prevent cracks.
Solution Approach 2:
The stress relief notch segments the continuous corner material by removing a portion of it, creating a discontinuity that interrupts stress flow paths. This segmentation prevents stress concentration from propagating through the corner, thereby preventing cracks while maintaining the simplicity of the overall chamfer structure.
2Reliability
If the terminal body is crimped onto the cable, then electrical connection is achieved, but cracks appear at the corner between side wing and connecting part
Solution Approach 1:
The stress relief notch provides localized structural modification at the corner position, creating a specific geometric feature that redistributes stress during crimping. This local quality change allows the corner to withstand crimping forces without cracking, thereby maintaining both electrical connection reliability and corner strength.
Solution Approach 2:
The stress relief notch is pre-formed into the terminal body structure before crimping occurs. This preliminary action prepares the corner area to handle the upcoming crimping stress by providing a stress-relief geometry in advance, preventing cracks from forming during the electrical connection process.
3Reliability
If cracks occur at the corner, then the terminal body integrity is compromised, but the insertion gap size changes affecting mating terminal insertion
Solution Approach 1:
The stress relief notch creates a localized structural feature that prevents crack propagation at the corner. By addressing the stress concentration issue locally, the overall terminal body integrity is maintained, which in turn preserves the dimensional stability of the insertion gap and ensures proper mating terminal insertion.
Solution Approach 2:
The stress relief notch acts as a pre-designed stress distribution feature that cushions the corner area against crimping forces. This beforehand cushioning prevents cracks from forming, thereby maintaining terminal body integrity and ensuring that the insertion gap dimensions remain within specified tolerances for proper mating terminal insertion.
Data Source
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AI summary
The present invention discloses a terminal body, a terminal, and a connector. The terminal body comprises of: a crimping part (11) adapted to be crimped onto a cable; a mating part (12) adapted to mate with a mating terminal; and a connecting part (13) connected between the crimping part (11) and the mating part (12). The crimping part (11) comprises of: a base (110) connected to the connecting part (13); and a pair of side wings (111) extending from both sides of the base (110) beyond the connecting part (13), respectively. A stress relief notch (1) is formed at a corner between the side wing (111) and the connecting part (13) to prevent local stress concentration. In the present invention, by forming a stress relief notch at the corner between the side wing and the connecting part of the terminal body, the stress concentration at the corner between the side wing and the connecting part of the terminal body can be fully eliminated, which ensures that there are no cracks in the terminal body when crimping the side wing, does not cause deformation of the mating part of the terminal body, and ensures that the size of the insertion gap of the mating part is not affected.