Electric Terminal Hood Form-Fitting Connection
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Solution Overview
Problem
Existing electric terminals with box-shaped hoods are cumbersome to manufacture, requiring a bending and welding process, which complicates the manufacturing steps and increases production costs.
Innovation Solution
The electric terminal features form-fitting connecting ends that eliminate the need for welding, using engagement arrangements to secure the connecting ends against movement in all directions, ensuring a secure and seamless assembly without damaging seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to secure the connecting ends of the sheet-metal part, then the structural integrity of the hood is improved, but the manufacturing complexity and production time increase
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a purely mechanical form-fitting connection system. The connecting ends are designed with complementary geometric features that interlock through bending and forming operations, eliminating the need for welding while maintaining structural integrity through precise mechanical engagement.
Solution Approach 2:
The patent changes the connection method from thermal welding to mechanical form-fitting connection by modifying the geometric parameters of the connecting ends. The connecting ends are designed with specific shapes and dimensions that enable form-fitting engagement, transforming the connection mechanism from thermal bonding to geometric interlocking.
2Strength
If welding is used to secure the connecting ends, then the structural integrity is improved, but the manufacturing time and productivity decrease
Solution Approach 1:
The patent replaces the welding process with a purely mechanical form-fitting connection system. The connecting ends are designed with complementary geometric features that interlock through bending and forming operations, eliminating the need for welding while maintaining structural integrity through precise mechanical engagement.
Solution Approach 2:
The patent incorporates the connection features directly into the bending and forming operations that create the hood structure. The geometric features for form-fitting engagement are formed during the initial shaping of the sheet-metal part, eliminating the need for separate welding operations and integrating the connection process into the primary manufacturing steps.
3Reliability
If the hood surface is made smooth to prevent seal damage, then the sealing reliability is improved, but the manufacturing complexity increases due to additional bending steps
Solution Approach 1:
The patent merges the seam formation with the overall hood structure. The form-fitting connection features are integrated into the hood's geometric design, and the seam is formed as part of the bending process that creates the hood shape. This eliminates the need for separate smoothing operations while maintaining the smooth surface required for seal protection.
Data Source
Figure 1
Figure 2~3
AI summary
An electric terminal 1 comprising a terminal body 2 and a box-shaped hood 3 enclosing at least partially the terminal body 2, said hood 3 being bent from a sheet-metal part into the box-shaped design wherein the sheet-metal part has a first connecting end 20 and a second connecting end 21 both being bent towards each other, wherein said connecting ends 20, 21 of the sheet-metal part are form-fittingly connected to each other.