Flat Wire Harness Terminal Clamping for Vibration-Reliable Assembly
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Solution Overview
Problem
Existing methods for attaching terminals to flat wiring members in vehicles face issues such as detachment due to vibration, complex assembly work, and limited contact reliability, particularly when using piercing terminals.
Innovation Solution
A connector-equipped wire harness design that includes a flat wiring member with dedicated terminals and a connector housing, where the terminals are clamped by the housing to enhance electrical connection and retention, allowing for simplified assembly and improved contact reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a piercing terminal is used to attach to flat wiring member, then terminal retention force is improved, but assembly work becomes complicated due to individual connection requirements
Solution Approach 1:
The patent combines multiple piercing terminals with a common base plate into a single integrated terminal assembly. This allows multiple electrical connections to be made simultaneously in one clamping operation, rather than requiring individual connection of each terminal. The base plate serves as a common mounting structure that holds multiple piercing terminals in fixed positions, enabling parallel assembly operations.
Solution Approach 2:
The piercing terminals are pre-positioned and fixed to the base plate before the clamping operation. This preliminary arrangement of terminals eliminates the need for individual positioning and connection during assembly. The base plate pre-organizes multiple terminals in their final positions, so that a single clamping action connects all terminals at once to the flat wiring member.
2Reliability
If a piercing terminal penetrates the flat wiring member, then electrical connection is achieved, but the flat wiring member may be damaged
Solution Approach 1:
The patent changes the connection parameters by using a clamping force that is sufficient to establish reliable electrical contact through the flat wiring member but controlled to remain below the threshold that would cause damage. The clamping structure applies distributed pressure across multiple contact points, converting a potentially damaging concentrated piercing force into a controlled compressive force that maintains electrical connection without compromising the wiring member integrity.
3Reliability
If piercing terminal attachment method is used, then contact reliability is improved, but attachment direction is limited to one side
Solution Approach 1:
The patent transitions from a one-dimensional piercing approach (single direction through the wiring member) to a two-dimensional clamping approach. The clamping structure applies force from multiple directions simultaneously, pressing the base plate with attached terminals against the flat wiring member from opposite sides. This multi-directional clamping achieves reliable electrical contact while providing flexibility in attachment orientation and accommodating variations in wiring member position.
Data Source
AI summary
A connector-equipped wire harness includes: a flat wiring member including an electric conductor; a flat wiring member-dedicated terminal including an electric connection portion that is electrically connected to a mating terminal and a narrow insertion portion that clamps the flat wiring member; and a connector housing that nips the flat wiring member-dedicated terminal. By nipping the flat wiring member-dedicated terminal by the connector housing while the flat wiring member is inserted into the narrow insertion portion, the electric conductor is clamped by the narrow insertion portion and the flat wiring member-dedicated terminal and the electric conductor are electrically connected to each other.