Integrated Connector Terminals and Detection Units
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Solution Overview
Problem
The existing connector designs require separate processes and increased costs due to the difference in shape between terminal fittings and detection terminals, leading to additional manufacturing steps.
Innovation Solution
A connector design where terminal fittings and detection terminals are formed in the same shape and integrated within the same housing, using a retainer with a pressing portion to ensure proper alignment and detection, reducing the number of processes and die costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If detection terminals are formed in a different shape from terminal fittings, then detection function can be achieved, but the number of manufacturing processes increases and cost increases
Solution Approach 1:
The patent combines the detection terminal and terminal fitting into a single integrated component. The detection terminal is formed as an integral part of the terminal fitting, eliminating the need for separate detection terminal components and reducing the number of manufacturing processes while maintaining the detection function through the integrated structure.
Solution Approach 2:
The terminal fitting is designed to serve multiple functions simultaneously: it provides electrical connection through its terminal function and enables detection through the integrated detection terminal function. This multi-functional design allows a single component to replace what would traditionally require separate parts, reducing manufacturing complexity.
2Reliability
If detection terminals are formed in a different shape from terminal fittings, then detection function can be achieved, but manufacturing cost increases
Solution Approach 1:
The detection terminal and terminal fitting are merged into a single integrated component that can be manufactured in one process. This eliminates the need for separate manufacturing operations and assembly steps, directly reducing manufacturing cost while preserving the detection function through the integrated design.
3Ease of operation
If pressing portion is disposed at position corresponding to terminal fittings, then terminal fittings can be pressed, but detection terminals cannot be properly pressed toward front wall
Solution Approach 1:
The retainer is designed with differentiated local characteristics: it has a pressing portion at the terminal fitting position to apply pressing force, and a pressing hole at the detection terminal position to allow pressing movement. This local differentiation enables each component to be properly pressed and positioned without interference from the other.
Solution Approach 2:
The retainer structure is segmented into distinct functional zones: a pressing portion for terminal fittings and a pressing hole for detection terminals. This segmentation allows independent control of pressing actions on different components, ensuring proper alignment and positioning of detection terminals while maintaining terminal fitting connection.
Data Source
Figure 1
Figure 2(A)~2(B)
Figure 3
AI summary
Provided is a connector in which terminal fittings and detection terminals can be formed at the same time. A housing (10) is provided with terminal fittings (20A) and a pair of detection terminals (20B). The terminal fittings (20A) are connected to ends of signal lines (70A), and electrically come into contact with counterpart terminal fittings (90A) provided in a counterpart housing (80) when both of the housings (10, 80) are fitted together. The pair of detection terminals (20B) are mutually energized thereby to close a detection circuit when both of the housings (10, 80) are properly fitted together. The pair of detection terminals (20B) are mutually connected via a detection line (70B) and formed in the same shape as the terminal fittings (20A).