Rectangular Wire Terminal Press-Fit Guide Groove Alignment
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Solution Overview
Problem
Existing connectors with rectangular wire terminals face issues of metal burrs generation and positional accuracy due to either lack of clearance or excessive contact pressure when press-fitted into connector housings, leading to defective continuity and accuracy problems.
Innovation Solution
The connector design incorporates press-fit portions on the rectangular wire terminal and guide grooves in the connector housing, with varying widths and depths to guide the press-fit portions, ensuring a secure press-fit without excessive contact, thereby preventing burr formation and maintaining positional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If clearance between cavity and rectangular wire terminal is increased, then burr generation is reduced, but positional accuracy deteriorates
Solution Approach 1:
The cavity is segmented into multiple sections: a first cavity portion with a first width that receives the terminal body, and a second cavity portion with a second width that receives the press-fit portion. This segmentation allows different clearance conditions in different regions, reducing burr generation at the press-fit interface while maintaining positional accuracy through the fitted first cavity portion.
Solution Approach 2:
Different regions of the cavity are given different dimensional characteristics. The first cavity portion has dimensions matched to the terminal body for precise positioning, while the second cavity portion provides appropriate clearance for the press-fit portion to minimize contact pressure and burr generation during insertion.
2Strength
If contact pressure between cavity and rectangular wire terminal is increased, then holding force is improved, but burr generation increases
Solution Approach 1:
The pressing action is segmented into two stages: first, the terminal body is positioned in the first cavity portion with appropriate fit; second, the press-fit portion is inserted into the second cavity portion with controlled clearance. This segmentation allows holding force to be developed without excessive contact pressure that causes burrs.
Solution Approach 2:
The terminal body is preliminarily positioned in the first cavity portion before the press-fit portion is fully inserted into the second cavity portion. This preliminary positioning ensures proper alignment and reduces the risk of excessive contact pressure and burr generation during the final pressing operation.
3Strength
If press-fit structure is provided in lateral direction, then holding force is improved, but burr generation increases
Solution Approach 1:
Instead of providing the press-fit structure in the lateral direction as in conventional designs, this invention inverts the approach by providing the press-fit structure in the longitudinal direction. The press-fit portion is formed on the longitudinal side surface of the terminal body and inserted into the second cavity portion, which reduces burr generation while maintaining holding force.
Data Source
AI summary
When a front end part of an upper surface of a first upper press-fit portion is brought into contact with a boundary part between a first terminal press-fit guiding groove and a second terminal press-fit guiding groove, the position of a rectangular wire terminal is thereafter accurately corrected along the first terminal press-fit guiding groove. That is, a distance from a lower surface of a terminal main body to the upper surface of the first upper press-fit portion coincides with a height from a lower surface of a cavity main part to the upper end of the first terminal press-fit guiding groove. As a result, the first press-fit portion reaches the first terminal press-fit guiding groove and thereafter, the rectangular wire terminal is further press-fitted, and forcibly pressed against the lower surface of the cavity main part.