Push-on Terminal Assembly with Compression Tabs

Solution Overview

Problem

Existing terminal assemblies for threaded post connections require torque wrenches and leverage to ensure secure mating, which can lead to cross-threading and loose connections, especially in confined spaces, and are not always accurately assembled due to the limitations of digital torque wrenches and tool grip issues.

Innovation Solution

A terminal assembly design featuring a terminal with compression tabs forming a channel and an interlocking mechanism, which securely mates with a barrel using a simple pushing motion, eliminating the need for torque measurement and leverage, and maintaining contact through elastic compression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rotating nut portion with internal threads is used for threaded post connections, then the terminal assembly can be securely fastened, but the assembly process becomes complex requiring torque wrenches and leverage, and cross-threading damage can occur

Engineering Contradiction:

Improvesecure fasteningVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The terminal assembly is divided into separate components: a barrel and a terminal body with compression tabs. This segmentation eliminates the need for a rotating nut portion and threaded connections, allowing the components to be pushed together in a single linear motion without complex assembly steps or risk of cross-threading

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using a rotating nut that threads onto a post, the invention inverts the connection mechanism by using compression tabs that push against the barrel from within. The terminal body is inserted through the barrel and secured by elastic compression rather than threaded engagement, completely reversing the traditional approach

Inventive Principle:

Principle #13The other way round (Inversion)

2Manufacturing precision

If digital torque wrenches are used to monitor torque and revolutions, then assembly accuracy can be improved, but the equipment cost increases and accuracy is not always sufficient to prevent improper assembly

Engineering Contradiction:

Improveassembly accuracyVSAvoidequipment complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The terminal assembly design is self-guiding and self-securing. The compression tabs are pre-configured to engage the barrel in a specific manner, and the elastic compression automatically ensures proper contact pressure. The design inherently prevents improper assembly without requiring external monitoring equipment

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention replaces the mechanical torque measurement system with a purely elastic mechanical connection. Instead of measuring torque and revolutions to ensure proper assembly, the elastic compression tabs naturally provide the correct contact force through their material properties and geometric configuration

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If torque wrenches are used to torque the rotating nut portion, then the connection can be secured, but cross-threading can still occur causing thread damage and expensive replacement

Engineering Contradiction:

Improveconnection securityVSAvoidthread damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The terminal assembly is divided into separate components: a barrel and a terminal body with compression tabs. This segmentation eliminates the need for a rotating nut portion and threaded connections, allowing the components to be pushed together in a single linear motion without complex assembly steps or risk of cross-threading

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention converts the potential harm of cross-threading into a benefit by completely eliminating threaded connections. The elastic compression tabs provide a connection method that is inherently resistant to cross-threading damage, turning the weakness of threaded connections into a strength of the new design

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Reliability

If tools are used to grasp and torque the rotating nut portion in confined spaces, then the connection can be secured, but proper leverage is difficult to obtain and loose connections can occur

Engineering Contradiction:

Improveconnection securityVSAvoidoperation difficulty

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Instead of using a rotating nut that threads onto a post, the invention inverts the connection mechanism by using compression tabs that push against the barrel from within. The terminal body is inserted through the barrel and secured by elastic compression rather than threaded engagement, completely reversing the traditional approach

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The terminal assembly design is self-guiding and self-securing. The compression tabs are pre-configured to engage the barrel in a specific manner, and the elastic compression automatically ensures proper contact pressure. The design inherently prevents improper assembly without requiring external monitoring equipment

Inventive Principle:

Principle #25Self-service

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 terminal assembly securely and quickly mates with its counterpart without requiring torque measurement or leverage, ensuring reliable mechanical and electrical contact, and simplifies the manufacturing process compared to traditional assemblies with rotating nut portions.

Implementation Method 1

The compression tabs 126 are elastically pressed against the conductive post 300

Methodology Applied

Scientific EffectElastic compression: Elasticity

Data Source

PatentUS7762856B2Push on terminal assembly

Publication Date: 2010.07.27 AMPHENOL CORP

AI summary

A terminal assembly includes a terminal and a barrel. The terminal has a coupling portion that fastens to a conductor, a mating portion with compression tabs arranged to form a channel, and an interlocking member on at least one of the compression tabs. The barrel is separate from the terminal and has a bore formed therethrough configured to receive the compression tabs of the mating portion. The barrel includes an interlocking member corresponding to the interlocking member of the at least one compression tab.