Male Terminal Locking Structure for Anti-Rotation and Overstress Protection
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Solution Overview
Problem
Electrical male terminals face issues with deformation and improper orientation during mating with connector assemblies, leading to potential disconnection and accidental removal, which can result in unintended falling out.
Innovation Solution
The electrical male terminal features a box-shaped design with a tang member and lever member that includes protruding members for overstress protection and orientation guidance, along with a protrusion on the lever member that deflects upward to secure the terminal within the connector assembly, preventing accidental removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the lever member is made flexible to enable locking action, then the locking function is improved, but the lever member becomes susceptible to deformation and overstress
Solution Approach 1:
A protruding member is provided on the lever member that engages with a corresponding recess in the main body to cushion and limit the flexing motion. This prevents excessive deformation while still allowing the lever member to flex sufficiently for locking action, thereby resolving the contradiction between operational flexibility and structural reliability
2Adaptability or versatility
If the tang member is made rotatable to enable orientation adjustment, then the adaptability is improved, but the terminal becomes susceptible to accidental rotation and unraveling
Solution Approach 1:
A protruding member on the tang member is preliminarily positioned to engage with a recess in the main body, establishing a predetermined rotational limit. This preliminary structural arrangement prevents accidental rotation while still allowing intentional orientation adjustment during assembly, resolving the contradiction between adaptability and stability
3Ease of repair
If the lever member is made easily removable for maintenance, then the ease of repair is improved, but the terminal becomes susceptible to accidental removal and falling out
Solution Approach 1:
The lever member is designed with dynamic characteristics that allow it to be easily manipulated during maintenance while providing inherent stability during normal operation. The protruding member engages with the recess to create a stable locked position, but the lever can be deliberately actuated to disengage for maintenance, resolving the contradiction between ease of repair and connection stability
Data Source
AI summary
An electrical male terminal of this invention includes a clamp or crimp area, a main body, and a blade. Protruding members and support members of the main body act as overstress protection. A panel shield member protects a protruding guide member. In another embodiment of this invention, a protruding member extends from a first support member of the main body, and a cut-out portion at the lower portion of the main body accommodates therein the protruding member to prevent the tang member from inadvertently or accidentally rotating relative to the lower portion of the main body. Furthermore, in this another embodiment of the electrical male terminal of this invention, a protrusion extends from the unattached end portion of the lever member for allowing the lever member to deflect upward when the protruding member of the unattached end portion interacts with an internal protrusion of a housing or connector assembly, thereby making it more difficult to remove the electrical male terminal from the housing or connector assembly, thereby protecting the electrical male terminal from inadvertently falling out during use.