Tool-Free Power Terminal Connection Plate for Reliable Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The conventional electrical connection structure between power supply units and electric wires in automobiles is complex, requiring screwing of nuts and precise torque management, which complicates the connection process and can lead to variations in work quality.
Innovation Solution
A structure using columnar and tubular terminals connected via a conductive connection plate, with a spring structure for multifaceted contact, and a cover to secure the connection, allowing for tool-free assembly and eliminating the need for nuts and torque management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nuts and screws are used to connect terminals and electric wires, then the connection can be securely fastened, but the work becomes complicated and requires torque management
Solution Approach 1:
The patent merges the terminal connection structure with the housing by forming columnar terminals directly on the housing surfaces. This integration eliminates the need for separate mounting structures and simplifies the connection process while maintaining secure electrical connections between power supply units and electric wires
Solution Approach 2:
The patent extracts and eliminates the nuts and screws from the connection system by using integrated columnar terminals that directly receive electric wires. This removal of fastening components simplifies the connection process and eliminates torque management requirements while maintaining connection reliability
2Reliability
If multiple nuts are screwed to each terminal, then the electrical connection is secured, but the work time increases and productivity decreases
Solution Approach 1:
The patent removes nuts and screws from the connection system entirely, replacing them with integrated columnar terminals that provide secure electrical connections without requiring multiple fastening operations. This extraction of fastening components directly improves productivity by eliminating time-consuming screwing operations
Solution Approach 2:
The patent segments the terminal function from the housing by forming distinct columnar terminals on the housing surfaces. This segmentation allows for simplified, tool-free connection of electric wires while maintaining the security and reliability of electrical connections
3Strength
If stud bolt type terminals are used, then the connection strength is sufficient for large current, but the assembly process becomes complex
Solution Approach 1:
The patent extracts the complex stud bolt mechanism and replaces it with simple columnar terminals formed directly on the housing. This extraction maintains sufficient connection strength for large current applications while dramatically improving ease of operation by enabling tool-free assembly
Solution Approach 2:
The columnar terminals are designed to self-align and self-secure electric wires without requiring external fastening tools or operations. The terminals provide inherent connection strength through their integrated design, eliminating the need for separate fastening operations
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
Simplifies the connection process, ensuring high reliability and consistency in electrical connections with reduced effort and no risk of nut-screwing errors, while maintaining strength and vibration resistance.
Implementation Method 1
a spring structure for multifaceted contact
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A structure of electrical connection is a structure of mutual electrical connection between a first power supply unit, a second power supply unit, and electric wires. The first power supply unit is provided with a first columnar terminal, and the second power supply unit is provided with a second columnar terminal. A tubular terminal is connected to an end of the electric wire. A first tubular terminal fitted to the first columnar terminal, a second tubular terminal fitted to the second columnar terminal, and a columnar terminal fitted to the tubular terminal are joined to a conductive connection plate. The entirety of the connection plate and the ends of the electric wires are covered with a cover.