Single-Bolt Terminal Connection Body for High-Current Contact Strength
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Solution Overview
Problem
Existing connector assemblies face issues with an increased number of components and insufficient contact strength for large currents, particularly in configurations involving fastening bolts and clip springs.
Innovation Solution
A connection body design featuring a first insulating plate with cutout portions, first and second terminals with flat plate shapes, and a second insulating plate with pressing portions, allowing for a single bolt to secure conductive contact between the terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fastening bolt and clip spring configuration is used to achieve connector assembly, then the connection can be secured, but the number of components increases and contact strength becomes insufficient for large currents
Solution Approach 1:
The patent combines the fastening function and electrical conduction function into a single integrated terminal structure. The U-shaped terminal body serves both as a mechanical fastener (replacing the separate fastening bolt and clip spring) and as an electrical conductor (replacing the separate conduction mechanism). This merging eliminates multiple components while ensuring both secure mechanical connection and reliable electrical contact for large currents
Solution Approach 2:
The U-shaped terminal body performs multiple functions simultaneously: it provides mechanical fastening through its U-shape configuration, ensures electrical conduction through its conductive material and contact surfaces, and maintains structural stability. This multi-functional design replaces the need for separate fastening bolts, clip springs, and conduction elements, thereby reducing component count while improving contact strength
2Reliability
If multiple components are used for fitting and conduction, then the connection can be achieved, but the manufacturing cost and size increase
Solution Approach 1:
By merging the fastening and conduction functions into a single U-shaped terminal body, the patent reduces the total number of components that need to be manufactured, assembled, and inspected. This integration simplifies the manufacturing process, reduces assembly steps, and lowers manufacturing costs while maintaining connection stability through the terminal's integrated design
3Reliability
If a conventional connector assembly with separate fastening and conduction elements is used, then the connection can be established, but the size of the assembly increases
Solution Approach 1:
The patent merges separate fastening elements and conduction elements into a single integrated U-shaped terminal body, significantly reducing the overall assembly size. The compact U-shaped design provides both mechanical fastening and electrical conduction in one component, eliminating the space required for separate bolts, clips, and conductor elements while maintaining strong connection capability
Solution Approach 2:
The terminal body's U-shape configuration creates a nested structure where the terminal itself forms the housing for the connection, eliminating the need for additional external housings or mounting structures. This nested design minimizes the overall volume of the connector assembly while ensuring robust mechanical and electrical connection
Data Source
AI summary
A second bolt insertion portion and a third bolt insertion portion have a following positional relationship in a connection body. The positional relationship is a positional relationship which allows fastening by insertion of a single bolt in a state in which base portions of a pair of first terminals are inserted into respective second cutout portions, a pair of second terminals are mounted on respective end portions of first contact portions, and a pair of first pressing portions are mounted on respective end portions of second contact portions. The fastening makes the first contact portions and the respective second contact portions conductive.