Flat Wiring Member Connection Structure for Compact Vehicle Assembly
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Solution Overview
Problem
The existing electric wire connection structures using connectors require larger mounting spaces and have low connection strength, making them prone to disconnection under strong forces, such as those encountered in vehicle accidents.
Innovation Solution
A wiring member connection structure that uses flat conductors with insulating coatings, bolts bonded perpendicularly to their surfaces, and through holes in counterpart conductors to create a direct and strong connection without the need for connectors or connection boxes, allowing for compact mounting and high connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connectors are used to connect electric wires, then the connection structure is standardized and easy to assemble, but the mounting space increases and connection strength decreases
Solution Approach 1:
The patent extracts and eliminates the connector component from the connection structure, directly connecting electric wires through terminal pieces with through-holes and fastening members. This removal of the insulating housing and terminal components reduces mounting space while maintaining assembly simplicity through the direct fastening mechanism.
Solution Approach 2:
The patent merges the functions of the connector housing, terminals, and fastening mechanism into a simplified integrated structure. The terminal piece combines the electrical connection function with the fastening function, eliminating the need for separate connector components and reducing overall mounting space.
2Ease of manufacture
If connectors with lock structures are used, then the assembly is easy, but the connection strength is insufficient under strong force
Solution Approach 1:
The patent employs a fastening member with a curved engagement surface that interfaces with the terminal piece. This curved geometry provides mechanical advantage and distributes stress more effectively, enhancing connection strength while maintaining ease of assembly through the snap-fit engagement mechanism.
Solution Approach 2:
The connection structure utilizes composite material properties by combining the electrical conductivity of metal terminals with the mechanical strength of the fastening member. The terminal piece integrates conductive material for electrical connection with structurally robust material for mechanical fastening, achieving both ease of assembly and high connection strength.
3Object-affected harmful factors
If connectors with insulating housings are used, then the electrical insulation is provided, but the size and mounting space increase
Solution Approach 1:
The patent extracts and removes the insulating housing from the connection structure, relying instead on the inherent insulation properties of the terminal piece material and the close-tolerance fit between components. This elimination of the bulky housing significantly reduces mounting space while maintaining adequate electrical insulation through alternative means.
Solution Approach 2:
The patent employs thin-film insulation layers and closely spaced component arrangements to provide electrical insulation without requiring bulky housings. The terminal piece incorporates insulating coatings or utilizes the natural insulation properties of the materials, achieving adequate electrical isolation in a compact form factor.
Data Source
AI summary
A wiring member connection structure is provided. The wiring member connection structure includes a flat wiring member formed by covering an outer circumference of a belt-like flat conductor with an insulating coating, a bolt that is erect and bonded perpendicularly to one conductor flat surface of the flat conductor exposed at a terminal of the flat wiring member where the coating is removed, a counterpart wiring member in which a through hole is provided at a terminal of a conductor so as to pass the bolt, and a nut that is screwed on the bolt inserted through the through hole to thereby conductively connect the flat conductor of the flat wiring member directly to the conductor of the counterpart wiring member.