Split-Plate Female Terminal for High-Current Connector Bending
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Solution Overview
Problem
The increase in current in on-board devices makes it difficult to manufacture female terminals with thicker metal flat plates, and the conventional structure results in high conduction resistance and poor heat radiation performance.
Innovation Solution
A female terminal design featuring a cylindrical connecting portion formed by deforming strip-shaped flat plates into arc shapes, with a wire connecting portion configured by overlapping the ends of these flat plates, allowing for direct continuity between the cylindrical connecting portion and the wire connecting portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the plate thickness of the metal flat plate is increased to handle higher current, then the current carrying capacity is improved, but the difficulty of cylindrical bending increases making manufacturing difficult
Solution Approach 1:
The metal flat plate is divided into two separate flat plate fittings, each forming a partial circumferential wall portion. This segmentation allows each piece to be more easily formed and bent into the required shape, avoiding the difficulty of bending a single thick plate into a complete cylinder.
Solution Approach 2:
The invention transitions from forming a complete cylindrical shape to creating two opposing arc-shaped wall portions with a gap between them. This dimensional change from closed cylinder to open arc structure reduces forming difficulty while maintaining current carrying capacity through the overlapping end portions.
2Ease of manufacture
If only a partial region of the cylindrical connecting portion is directly coupled to the wire connecting portion, then the manufacturing process is simplified, but the conduction resistance increases and heat radiation performance degrades
Solution Approach 1:
The electrical connection path is segmented into multiple regions along the circumferential direction. The first and second other end portions are positioned to overlap, creating multiple direct coupling points between the cylindrical connecting portion and wire connecting portion, thereby reducing overall conduction resistance while maintaining manufacturing simplicity.
3Ease of manufacture
If only a partial region of the cylindrical connecting portion is directly coupled to the wire connecting portion, then the manufacturing process is simplified, but the heat radiation performance degrades
Solution Approach 1:
The heat radiation function is distributed across multiple regions through the overlapping end portions. This creates multiple direct thermal coupling paths between the cylindrical connecting portion and wire connecting portion, improving overall heat radiation performance while keeping the manufacturing process simple.
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
This design facilitates easy manufacturing even with thicker plates, reduces conduction resistance, and improves heat radiation performance compared to conventional structures.
Implementation Method 1
a first circumferential wall portion provided by deforming one end portion of a first flat plate fitting having a strip shape to be curved into an arc shape and a second circumferential wall portion provided by deforming one end portion of a second flat plate fitting having a strip shape into an arc shape
Implementation Method 2
The wire connecting portion is configured by overlapping a first other end portion which is the other end portion of the first flat plate fitting and a second other end portion which is the other end portion of the second flat plate fitting
Data Source
AI summary
A female terminal includes a cylindrical connecting portion to be conductively connected to a columnar connecting portion of a male terminal, and a wire connecting portion to which a core of a wire is to be connected. The cylindrical connecting portion has a first circumferential wall portion provided by deforming one end portion of a first flat plate fitting having a strip shape to be curved into an arc shape and a second circumferential wall portion provided by deforming one end portion of a second flat plate fitting having a strip shape into an arc shape. The wire connecting portion is configured by overlapping a first other end portion which is the other end portion of the first flat plate fitting and a second other end portion which is the other end portion of the second flat plate fitting.