Reinforced Female Terminal Structure for Unseated Lock Detection
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Solution Overview
Problem
Existing female electrical terminals can be improperly seated within connectors, leading to false indications of full installation and potential electrical malfunctions due to the secondary lock crushing the rearward end of the box-like structure if not fully seated, causing the secondary lock to close prematurely.
Innovation Solution
The female electrical terminal design includes a longitudinally extending box portion with structural reinforcements such as a tab and cutout, lateral indentations, and a folded end portion that inhibit crushing and prevent the secondary lock from moving to the closed position if the terminal is unseated, providing a visual indication of improper seating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the secondary lock is pushed inward to retain female electrical terminals, then the secondary lock closes to provide retention, but if the terminal is not fully seated, the secondary lock may crush the rearward end of the box-like structure giving a false indication of proper installation
Solution Approach 1:
The patent applies preliminary anti-action by providing structural reinforcements (tab and cutout, lateral indentation, folded end portion) to the box portion before the secondary lock is engaged. These reinforcements preemptively prevent crushing damage that would otherwise occur when the secondary lock is pushed inward against an unseated terminal, thereby eliminating the false indication problem while maintaining reliable retention functionality.
2Strength
If the box portion is made more robust to prevent crushing, then damage resistance improves, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the box portion into distinct functional elements: a tab and cutout feature, a lateral indentation, and a folded end portion. Each segment serves a specific reinforcement purpose, distributing the structural support function across multiple simple geometric features rather than requiring a single complex robust structure, thereby maintaining strength while controlling overall complexity.
Solution Approach 2:
The patent applies local quality by concentrating structural reinforcements only at the rearward end of the box portion where crushing damage is most likely to occur during secondary lock engagement. The tab and cutout, lateral indentation, and folded end portion are strategically positioned to provide localized strength precisely where needed, without adding unnecessary complexity to other portions of the terminal structure.
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3B
AI summary
A female wire terminal (22) includes a box (33) extending longitudinally from a crimp end (34) to an open forward end (36) that is configured to receive a male wire terminal. The box (33) is provided by upper and lower walls (58, 64) joined by a first lateral wall (60). A second lateral wall (62) is joined to the lower wall (64) opposite the first lateral wall (60). The upper wall (58) provides a protrusion (46) that is configured to cooperate with an electrical connector (10). The upper wall (58) overlaps and abuts at a rearward end (38) of a longitudinal edge (66) of the second lateral wall (62) opposite the first lateral wall (60). The rearward end (38) is opposite the open end (36).