Electrical Terminal Buttjoint Groove Orientation
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Solution Overview
Problem
Existing electrical connectors face issues with terminal deformation and incorrect orientation during assembly, leading to defective connectors due to the lack of a stable fixing mechanism and reliance on visual judgment for positioning.
Innovation Solution
The electrical terminal features a buttjoint portion with a stamped groove for enhanced stability and an elastic buckling member, along with a positioning structure to ensure correct orientation, preventing deformation and assembly errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If two sheets are bent and butt jointed to form a tube structure, then the terminal body can be formed to match terminal insertion hole shapes, but the connection is merely maintained by permanent deformation and the two sheets are easily deformed and separated
Solution Approach 1:
The terminal body is divided into two separate sheets that are bent and butt jointed together to form the tube structure. This segmentation allows the terminal body to be formed to match different terminal insertion hole shapes while maintaining manufacturing flexibility.
Solution Approach 2:
A stamped groove is formed at the buttjoint portion before assembly into the terminal insertion hole. This preliminary action creates a mechanical interlocking feature that prevents the two sheets from separating, thereby stabilizing the tube structure before the terminal is fully assembled.
Solution Approach 3:
The stamped groove is localized at the buttjoint portion where the two sheets meet, providing enhanced stability specifically at this critical connection point without affecting the overall terminal body structure or its ability to match different insertion hole shapes.
2Ease of manufacture
If the mounting portion is positioned at one side of the tube structure, then the terminal can be mounted, but the positioning depends on visual judgment which is prone to errors
Solution Approach 1:
The mounting portion is positioned asymmetrically at one side of the tube structure, extending from the rear edge in a direction perpendicular to the first direction. This asymmetric positioning, combined with the stamped groove orientation, creates a unique configuration that guides correct orientation during assembly.
Solution Approach 2:
The stamped groove and mounting portion configuration enable the terminal to self-align during assembly. The asymmetric mounting portion naturally guides the terminal into the correct orientation when inserted into the terminal insertion hole, eliminating the need for visual judgment by the assembler.
3Ease of operation
If visual judgment is used for positioning mounting portions, then assembly can be performed, but errors are generated resulting in defective connectors
Solution Approach 1:
The stamped groove is formed at the buttjoint portion before assembly, creating a mechanical guide feature that ensures correct orientation during insertion. This preliminary structural preparation eliminates the need for visual judgment during assembly, thereby preventing positioning errors and improving connector quality.
Solution Approach 2:
The stamped groove acts as an intermediary feature between the terminal body and the terminal insertion hole. It provides a mechanical reference that mediates the positioning process, ensuring correct orientation without relying on the assembler's visual judgment.
Data Source
AI summary
An electrical terminal includes a terminal body and a mounting portion. The terminal body has a front edge, a rear edge, and two opposite lateral edges. At least part of the terminal body is bent, and the two lateral edges are butt jointed to form a buttjoint portion. The buttjoint portion has a joint seam between the two lateral edges which are butt jointed, and the buttjoint portion further includes a stamped groove spanning the joint seam. The mounting portion extends from the terminal body. An electrical connector is also provided, which includes a base and the electrical terminal.