Terminal Cap Forming via Dipping for Rapid Attachment
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Solution Overview
Problem
Conventional terminals face challenges in uniformly applying adhesive to caps and securing them to terminal fittings, leading to increased time and complexity in the attachment process.
Innovation Solution
A terminal design featuring a tubular insertion part with a reduced annular portion at the tip, where a resin-made cap is formed by dipping, with an embedded part inside the insertion part and an exposed part covering the annular portion, allowing for quicker cap attachment and reduced formation work.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is preliminarily applied to the shaft of the cap before insertion, then the cap can be attached to the terminal fitting, but it is difficult to uniformly apply the adhesive and the attachment process takes time
Solution Approach 1:
The cap is preliminarily formed with a projection that fits into a groove on the terminal fitting, establishing mechanical interlocking before final assembly. This preliminary geometric configuration ensures proper alignment and facilitates rapid attachment without requiring time-consuming adhesive application steps.
Solution Approach 2:
The adhesive-based mechanical bonding system is replaced with a geometric interlocking system using the projection-groove mechanism. This substitution eliminates the need for uniform adhesive application and curing time, achieving both reliable attachment and reduced process time through pure mechanical engagement.
2Object-affected harmful factors
If a cap is attached to prevent damage to the terminal housing and female terminal fitting, then protection is provided, but the attachment process becomes more complex and time-consuming
Solution Approach 1:
The protective cap and the attachment mechanism are merged into a single integrated component. The cap body incorporates the projection feature, combining the protection function with the attachment function in one element, thereby simplifying the overall assembly process while maintaining damage protection capabilities.
Solution Approach 2:
The cap's projection automatically engages with the groove on the terminal fitting during insertion, providing self-alignment and self-attachment. This self-service mechanism eliminates the need for separate alignment or fastening operations, reducing complexity while ensuring the cap is properly positioned for protective function.
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 streamlines the cap attachment process, reducing time and effort while improving productivity by eliminating the need for separate cap attachment work and simplifying the formation of the annular portion through pressing.
Implementation Method 1
a resin made cap disposed at the tip of the insertion part, the resin made cap being provided by a dipping work
Data Source
Figure 1~2
Figure 3~5
Figure 6A~6D
AI summary
Disclosed are a terminal allowing work for attaching the cap to the insertion part to eliminate, and to provide in a short time the cap to the insertion part, and a method of forming the cap of the terminal. In a terminal 1, at a tip end of a tubular insertion part (3) a resin made cap (6) is provided, the insertion part includes an annular portion with narrower diameter than that the insertion part at a tip end thereof, the cap is disposed at the insertion part by a dipping work covering the annular portion in an inner side away from a tip end of the insertion part (3a) past the annular portion.