EV Female Terminal Support Structure for Stable Mating Alignment
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Solution Overview
Problem
Existing electrical connection systems for automotive applications face challenges such as difficulty in maintaining the female terminal in a central position, potential damage during mating, and susceptibility to movement leading to damage or improper assembly.
Innovation Solution
The proposed electrical connection system includes a female terminal with a first elongate portion oriented parallel to the mating direction, a second elongate portion oriented differently, and a bent portion with a supporting member that prevents movement of the female terminal within the outer housing, ensuring proper alignment and reducing the risk of damage during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the female terminal is made flexible with bends to allow orientations, then adaptability is improved, but positioning stability deteriorates
Solution Approach 1:
The female terminal is divided into distinct segments: a first elongate portion for insertion, a bent portion with supporting members for positioning, and a second elongate portion for wire connection. This segmentation allows each part to fulfill its specific function - the bent portion provides structural support and positioning stability while the elongate portions provide flexibility for orientation and connection.
2Ease of manufacture
If the female terminal is not fixed in the outer housing, then ease of assembly is improved, but reliability deteriorates due to movement and potential damage
Solution Approach 1:
The supporting members are pre-formed as integral parts of the female terminal before assembly. These supporting members are preliminarily shaped to engage with the outer housing, so that during assembly the terminal automatically positions itself correctly without requiring additional fixation steps. This preliminary formation of positioning structures ensures both easy assembly and reliable positioning.
3Adaptability or versatility
If the female terminal is bent at 90 degrees for flexible arrangement, then adaptability is improved, but manufacturing precision deteriorates due to difficulty in keeping central position
Solution Approach 1:
The supporting members on the bent portion serve themselves by automatically engaging with corresponding structures in the outer housing. This self-positioning mechanism eliminates the need for external alignment tools or complex positioning procedures during manufacturing. The terminal's own structure provides the positioning function, ensuring consistent central alignment while maintaining the required 90-degree bend for flexible arrangement.
Data Source
AI summary
This disclosure relates to an electrical connection system for automotive applications, featuring an outer housing with a defined mating direction and a female terminal. The female terminal includes a first elongate portion aligned parallel to the mating direction and partially housed within the outer housing, a second elongate portion oriented differently, and a bent portion between them. The first elongate portion has a receiving end for mating with a male terminal, while the bent portion includes supporting members to secure the female terminal within the outer housing, preventing movement. This innovative design ensures stable and reliable electrical connections in automotive systems.