Plastic Shell for Connection Terminal with Segmented Clamping
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Solution Overview
Problem
Existing electrical connector technologies face challenges with unstable and inefficient manufacturing processes due to unreasonable design and defects in terminal plastic shell structures, leading to low production efficiency and complex manufacturing.
Innovation Solution
A plastic shell design with a main body featuring a top and bottom surface, a wire insertion hole, and a clamping mechanism with elastic members, forming a hollow shell shape for efficient wire insertion and clamping, which simplifies manufacturing and enhances contact quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing terminal plastic shell structures are used, then electrical connection function is achieved, but manufacturing complexity increases and production efficiency decreases
Solution Approach 1:
The plastic shell is divided into multiple independent components including upper shell, lower shell, insulating pieces, and positioning structures. Each component can be manufactured separately and assembled through snap-fit connections, enabling modular production and reducing overall manufacturing complexity while maintaining functional integrity.
Solution Approach 2:
The patent integrates multiple functions into unified structures: the positioning piece simultaneously provides electrical insulation and mechanical positioning; the clamping structure combines wire securing with structural support; the integrated design merges upper and lower shells into a cohesive assembly unit, simplifying the manufacturing process.
2Reliability
If existing terminal plastic shell structures are used, then electrical connection is achieved, but design rationality is poor leading to defective construction
Solution Approach 1:
Different regions of the plastic shell are designed with specialized properties: insulating pieces are positioned at electrical contact points to prevent short circuits; positioning structures are located at critical interfaces to ensure precise alignment; clamping portions are designed with specific geometries to securely hold wires. Each local area is optimized for its specific function, eliminating design defects.
Solution Approach 2:
The plastic shell incorporates pre-designed positioning features, pre-formed clamping structures, and pre-positioned insulating elements that guide the assembly process. These preliminary actions ensure correct component placement and wiring configuration before final assembly, preventing construction defects and ensuring reliable electrical connections.
3Ease of manufacture
If conventional plastic shell designs are used, then basic mounting function is provided, but batch manufacturing convenience is poor
Solution Approach 1:
The shell is segmented into standardized components that can be manufactured using injection molding or similar mass production techniques. Each segment is designed with uniform features that facilitate automated assembly, enabling efficient batch production while maintaining high production throughput.
4Reliability
If existing terminal structures are used, then electrical connection is achieved, but contact quality stability is poor
Solution Approach 1:
The patent implements precise positioning features at critical contact points, including positioning pieces with specific geometries that ensure accurate alignment between terminals and wiring. These localized quality enhancements at connection interfaces stabilize contact quality without requiring complex overall configuration.
Solution Approach 2:
Pre-formed positioning structures and alignment features are built into the plastic shell design, ensuring that terminals and wires are correctly positioned before electrical contact is established. This preliminary positioning action guarantees stable contact quality while maintaining relatively simple device configuration.
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
The solution improves manufacturing efficiency, reduces production costs, and enhances the stability and reliability of electrical connections by providing a convenient and efficient design for batch production and maintenance, while ensuring alignment and detection operations.
Implementation Method 1
The clamping joint is composed of a pair of elastic members, and free ends of the two elastic members form inner bending structures and the inner bending structures are symmetrically arranged in the contact frame, so that the wire is clamped elastically after the wire enters into a wire passing channel
Data Source
AI summary
A plastic shell for mounting a connection terminal includes a main body configured as an integral single component. The main body includes a top surface and a bottom surface opposed to each other. The bottom surface is depressed toward the top surface to form an internal space for accommodating a conductive terminal. A connecting portion for mating with the clamping portion of the conductive terminal is disposed in the internal space. A front end surface of the main body has a wire insertion hole for inserting a wire into the conductive terminal, and the wire insertion hole is in communication with the internal space.