Rubber Plug Holding Structure for Compact Sealed Terminals
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Solution Overview
Problem
The existing rubber plug holding structure for terminals is prone to breakage during crimping, leading to potential water ingress and circuit disconnection, and results in increased terminal size and cost due to multiple projections on the barrel piece.
Innovation Solution
A terminal design featuring a second press-fastening piece formed from a remaining carrier piece, which press-fastens the rubber plug's outer periphery, with options for planar, concave arc, or convex arc shapes, and folding configurations to enhance holding force without increasing size or cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If multiple projections are formed on the barrel piece to enhance holding force, then the holding force against the rubber plug is improved, but the width and overall length of the terminal are increased
Solution Approach 1:
The patent combines the holding function with the existing connecting piece structure. The connecting piece, which originally served only to connect multiple terminals on a carrier, is modified to also provide holding force against the rubber plug through its edge portions. This merging of functions eliminates the need for separate projection structures, maintaining holding force while avoiding increased terminal dimensions.
2Force
If multiple projections are formed on the barrel piece to enhance holding force, then the holding force against the rubber plug is improved, but the manufacturing cost is increased
Solution Approach 1:
The connecting piece is designed to serve multiple functions: it connects multiple terminals when formed from a chain terminal, and simultaneously provides holding force against the rubber plug through its edge portions. This multi-functionality eliminates the need for additional projection structures that would require separate manufacturing processes, thereby reducing manufacturing complexity and cost while maintaining effective holding force.
3Reliability
If the terminal structure is modified to prevent rubber plug breakage, then the reliability is improved, but the device complexity is increased
Solution Approach 1:
The patent converts the potentially harmful edge portions of the connecting piece, which could bite into and break the rubber plug, into a beneficial holding mechanism. By strategically positioning and shaping these edge portions, they provide secure holding force against the rubber plug without causing breakage. This approach maintains structural simplicity while improving reliability, as the same structural features serve both connection and holding functions without requiring additional protective elements.
Data Source
AI summary
A rubber plug holding structure for a terminal. The structure includes an electric wire that has a core wire and an insulating coating which coats the core wire; a rubber plug through which the electric wire is inserted and which seals a gap with the electric wire; and a terminal that has a first press-fastening piece which press-fastens an outer periphery of the rubber plug. The terminal also has a second press-fastening piece that is formed from a portion of the terminal which remains after cutting a connecting piece serving as a connecting portion of a carrier when the terminal is formed from a chain terminal. The second press fastening piece is press-fastened against a part of the outer periphery of the rubber plug.