Power Terminal Crimping Wings Weld Area Single Pin
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Solution Overview
Problem
Existing power terminal solutions require two terminals to connect two different wires to a single male pin on a power supply, necessitating two separate welding steps.
Innovation Solution
A power terminal with a weld area between two pairs of insulation crimping wings allows for a single terminal to connect two ends of a single wire to a power supply, eliminating the need for multiple terminals by aligning crimping wings and weld area along a longitudinal axis and positioning the power connector transversely to accommodate a male pin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two power terminals are used to connect two different wires to a single male pin, then reliable electrical connection is achieved, but the number of welding steps increases and connection time is extended
Solution Approach 1:
The patent combines two separate power terminals into a single integrated power terminal that can connect two different wires to a single male pin simultaneously. The single power terminal includes a first crimping wing for connecting a first wire and a second crimping wing for connecting a second wire, both to the same male pin, thereby reducing the number of welding steps from two to one while maintaining reliable electrical connections.
Solution Approach 2:
The single power terminal is designed with multi-functional capability to perform multiple connection functions. It can simultaneously connect different wires of the same color or different colors to a single male pin, replacing the need for multiple single-function terminals and enabling faster assembly operations.
2Reliability
If two power terminals are used to connect wires to a power supply, then adequate electrical connection is achieved, but the complexity of the connection process increases
Solution Approach 1:
The patent merges multiple power terminals into a single integrated component that performs the function of multiple terminals. The single power terminal includes multiple crimping wings that can simultaneously connect multiple wires to a single male pin, simplifying the overall connection process and reducing the number of components that need to be assembled and welded.
3Productivity
If a single power terminal connects two ends of a single wire, then the number of welding steps is reduced, but the structural design becomes more complex
Solution Approach 1:
The power terminal is segmented into distinct functional components including a first crimping wing for connecting a first end of the wire and a second crimping wing for connecting a second end of the wire. Each crimping wing is designed to engage with insulation of the wire, while the terminal body provides a common connection point for both wings to connect to the male pin, enabling simultaneous connection of both wire ends in a single welding operation.
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
This configuration enables a faster, more efficient connection of two wires to a power supply with improved weld quality and reduced bending moments, allowing for a robust and secure mechanical and electrical connection using a single power terminal.
Implementation Method 1
A power terminal (1) suitable for crimping and welding to an insulated electrical wire (6)
Data Source
Figure 1~2
AI summary
The invention relates to a power terminal (1) comprising a first pair of insulation crimping wings (4) and a second pair of insulation crimping wings (5) for crimping to an insulation (3) of an insulated electrical wire (6). The terminal comprises a weld area (7) provided between the first pair of insulation crimping wings (4) and the second pair of insulation crimping wings (5) for welding to a lead (9) of the insulated electrical wire (6). The length (LW) of the weld area (7) is substantially equal to the length (LL) of the lead (9). The power terminal comprises power connector (10) in conductive contact with the weld area (7).