Folded Spring Terminal Fitting for Connector Tolerance Variation
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Solution Overview
Problem
The existing connector with a cantilever-shaped leaf spring has a small displacement amount in the connection direction, leading to concerns about maintaining conductivity when component dimensions vary.
Innovation Solution
A terminal fitting with a box portion, base portion, contact portion, and spring portion, where the spring portion is shaped with elongated plate portions folded and linked to provide a large displacement amount, ensuring reliable connection even with varying dimensions, and a chain terminal with terminal fittings projecting from a carrier, featuring a crimping portion and spring portion arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single leaf spring with cantilever shape is used, then the structure is simple, but the displacement amount in connection direction is small
Solution Approach 1:
The spring portion is divided into multiple plate portions (first plate portion, second plate portion, third plate portion) that are folded and linked together. This segmentation allows each plate portion to contribute to the overall displacement, achieving a larger total displacement amount while maintaining structural simplicity through the modular folded design.
2Adaptability or versatility
If component dimensions vary in connection direction, then manufacturing flexibility is improved, but connection reliability deteriorates
Solution Approach 1:
The spring portion is designed to be resilient and displaceable in the insertion direction of the mating terminal. This dynamic capability allows the contact portion to automatically adjust its position to maintain reliable electrical contact even when component dimensions vary within tolerance ranges, thereby maintaining connection reliability despite dimensional variations.
3Force
If a resilient leaf spring is used to generate contact pressure, then conductivity is achieved, but displacement capability is limited
Solution Approach 1:
The spring portion utilizes a folded configuration where plate portions are arranged in multiple dimensions (folded back and forth). This dimensional arrangement allows the spring to generate contact pressure through resilience while simultaneously providing a larger overall displacement amount in the insertion direction, as the folded structure can extend and compress along the insertion direction while maintaining contact force.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration maintains connection reliability to a mating terminal by securing a large displacement amount and distributing loads effectively, reducing the risk of fatigue and ensuring consistent conductivity.
Implementation Method 1
the spring portion being shaped such that a plurality of plate portions elongated in a direction intersecting the insertion direction are folded and linked while being spaced apart in the insertion direction
Data Source
AI summary
It is aimed to provide a terminal fitting and a chain terminal capable of maintaining connection reliability to a mating terminal. A terminal fitting (45) is provided with a box portion 46, into which a mating terminal 18 is inserted from front, a base portion (47) fixed in the box portion (46), a contact portion (48) arranged forward of the base portion (47) and configured to electrically contact the mating terminal (18) being inserted into the box portion (46), and a spring portion (49) provided to link the base portion (46) and the contact portion (48) and support the contact portion (48) displaceably in an insertion direction (R) of the mating terminal (18). The spring portion (49) is shaped such that a plurality of plate portions (49A) elongated in a direction intersecting the insertion direction (R) are folded and linked while being spaced apart in the insertion direction (R).