Slider Terminal Wire Assembly for Low-Cost Reliable Connection
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Solution Overview
Problem
The existing terminal wire assembly requires large equipment and dies for crimping, leading to increased production costs and equipment investment.
Innovation Solution
A terminal assembly featuring a terminal body and slider, where the terminal body is formed from a folded metal sheet with holding protrusions that deform to securely hold the electric wire, reducing production costs and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a folded metal sheet is used to form the terminal body with holding protrusions, then production cost is reduced and equipment investment is minimized, but the reliability of electric connection must be maintained
Solution Approach 1:
The holding protrusions are formed by self-foldings of the metal sheet during the forming process, allowing the terminal body to create its own wire-holding structures without requiring separate forming equipment or additional manufacturing steps. This self-service mechanism reduces production cost while ensuring reliable electric connection through properly formed holding protrusions
Solution Approach 2:
The metal sheet is pre-formed with folded portions that will become holding protrusions before the actual crimping operation. This preliminary action ensures that the holding protrusions are already in position and properly shaped to securely hold the wire, maintaining connection reliability while avoiding the need for complex equipment during production
2Reliability
If holding protrusions are formed on the holding section, then the electric wire is properly held and connection reliability is improved, but production cost may increase due to formation complexity
Solution Approach 1:
The holding protrusions form themselves through the folding of the metal sheet during terminal body formation, without requiring separate forming operations or specialized equipment. This self-service approach ensures proper wire holding for reliable connection while keeping production cost low
Solution Approach 2:
The formation of holding protrusions is merged with the terminal body forming process itself. The folded portions that create holding protrusions are integrated into the overall terminal body structure, eliminating the need for separate forming steps and reducing production cost while maintaining connection reliability
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 solution reduces production costs and enhances the reliability of the electric connection between the terminal and the electric wire while minimizing equipment investment.
Implementation Method 1
The terminal body is formed from a folded metal sheet. The holding section includes a holding protrusion that protrudes toward the electric wire and contacts the electric wire. The holding protrusion is formed from a folded metal sheet.
Data Source
AI summary
A terminal coupled to an end of an electric wire on a front side with respect to an extending direction in which the electric wire extends. The terminal includes a terminal body including a holding section holding the electric wire and a slider slidable relative to the terminal body in the extending direction. The slider includes a pressing portion that presses the holding section toward the electric wire. The terminal body is formed from a folded metal sheet. The holding section includes a holding protrusion that protrudes toward the electric wire and contacts the electric wire. The holding protrusion is formed from a folded metal sheet.