Insert Sheet Terminal Structure for Low-Force Reliable Contact
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Solution Overview
Problem
Existing F-type elastic sheet terminals require high insertion force due to elastic protrusions on the bottom and top walls, leading to potential deformation and poor contact when subjected to external forces.
Innovation Solution
The terminal design features a slot delimited by a flat bottom wall, a top wall with a protrusion and reinforcing ribs, and side walls formed by bending the bottom wall upwards, reducing insertion force and preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protrusions are added on both the bottom wall and top wall to elastically press on the insert sheet, then the connection reliability is improved, but the insertion force required increases significantly
Solution Approach 1:
The patent removes the protrusion from the bottom wall, extracting only the necessary elastic pressing function from the top wall protrusion. This eliminates the conflicting elastic forces that caused high insertion force requirements while maintaining connection reliability through the retained top wall protrusion and bent side wall structure.
Solution Approach 2:
The patent transitions from a symmetric design (protrusions on both bottom and top walls) to an asymmetric design (protrusion only on top wall with bent side walls). This asymmetric configuration reduces insertion force by eliminating the opposing bottom wall protrusion while maintaining securing function through the top wall protrusion and side wall bending geometry.
2Reliability
If symmetric protrusions are used on the bottom wall and top wall, then the insert sheet is securely held, but the terminal deforms easily under external forces
Solution Approach 1:
The patent replaces the symmetric protrusion configuration with an asymmetric structure featuring a top wall protrusion and bent side walls. This asymmetric design prevents the terminal from acting as a lever under external forces, eliminating the deformation issue while maintaining secure holding through the protrusion and bent geometry.
Solution Approach 2:
The patent introduces a new dimensional element by bending the side walls upward to form hooks that engage with the insert sheet. This adds a lateral securing dimension beyond the vertical protrusion, enhancing holding security without creating the fulcrum effect that causes deformation.
3Reliability
If protrusions on the bottom wall act as fulcrums, then the insert sheet is retained, but the entire terminal deforms under moment loads
Solution Approach 1:
The patent extracts the fulcrum element (bottom wall protrusion) that causes deformation under moment loads. Retention function is maintained through the top wall protrusion and bent side walls, which secure the insert sheet without creating a lever arm that would amplify deformation stresses.
Solution Approach 2:
The bent side walls extend into a new spatial dimension, creating hooks that engage the insert sheet laterally. This dimensional change provides retention security without relying on bottom wall protrusions that act as fulcrums, thereby preventing deformation under moment loads.
Data Source
AI summary
A terminal comprises an insert sheet connecting part and a cable connecting part. The insert sheet connecting part defines a slot sized to receive an insert sheet. The slot is delimited by a bottom wall, a top wall and two side walls. The two side walls are formed by upwardly bent extensions of left and right sides of the bottom wall. The top wall defines two top wall portions formed by inwardly bent portions of the two side walls respectively. The top wall includes a protrusion extending toward the bottom wall, and a reinforcing rib extending from one side wall to the corresponding top wall portion formed by bending the one side wall.