Terminal Connection Structure Using Clip Terminals
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Solution Overview
Problem
Existing terminal connection structures for high-voltage power supply devices in hybrid or electric vehicles are bulky due to the need for thick cables and terminal blocks, leading to increased electrical resistance and limited miniaturization potential.
Innovation Solution
A terminal connection structure where electrical contact portions of terminal fittings are connected by clip terminals with urging connection portions, allowing the contact pieces to approach each other perpendicularly, thereby sandwiching the contact portions and reducing the width of the connection, using aluminum alloy and harder metals to ensure reliable contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple terminal fittings are positioned on the same plane to enable easy screwing of bolts and nuts, then ease of operation is improved, but the width of the terminal connection structure increases
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement of terminal fittings to a three-dimensional stacked configuration. Terminal fittings are arranged in multiple layers along the width direction, with clipping members extending from the housing to clamp the fittings in each layer. This dimensional change allows multiple terminal fittings to be connected without increasing the overall width significantly, while maintaining ease of operation through the clipping mechanism.
2Reliability
If terminal fittings are connected using bolts and nuts screwed together, then reliability of connection is improved, but device complexity increases
Solution Approach 1:
The patent extracts the fastening function from the terminal fittings themselves and relocates it to separate clipping members. The clipping members are independently configured to clamp the terminal fittings, separating the connection function from the terminal fitting structure. This reduces the complexity of individual terminal fittings while maintaining reliable connection through the dedicated clipping mechanism.
Solution Approach 2:
The clipping members act as intermediary elements between the housing and the terminal fittings. Instead of directly screwing bolts and nuts to connect terminal fittings, the clipping members mediate the connection by clamping the fittings in place within the housing. This intermediary mechanism simplifies the overall connection structure while ensuring reliable electrical connection.
3Reliability
If thick cables are used to transmit high voltage current, then reliability of power transmission is improved, but volume of the connection structure increases
Solution Approach 1:
The patent merges multiple terminal fittings and their connections into a single integrated housing structure. Multiple terminal fittings are stacked and connected within the same housing volume, allowing thick cables to be connected in a compact arrangement. This merging approach maintains reliable power transmission for high voltage currents while significantly reducing the overall volume compared to separate connection structures.
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 configuration enables reliable and miniaturized connections between terminal fittings, reducing the overall width of the connection structure and ensuring low electrical resistance, thus improving the efficiency and compactness of power supply connections in vehicles.
Implementation Method 1
an urging connection portion which urges a pair of the contact pieces in a direction to approach each other
Data Source
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AI summary
A terminal connection structure which enables miniaturization and reliable connection of terminal fittings to each other is provided. A terminal connection structure 1 includes first terminal fittings 5 connected to a motor 7, second terminal fittings 22 connected to an inverter, and a clip terminal. The first terminal fittings 5 and the second terminal fittings 22 respectively includes electrical contact portions 8 and 27 formed in a band plate shape and superimposed on each other. The clip terminal includes a pair of contact pieces sandwiching the electrical contact portions 8 and 27 where the clip terminals are superimposed on each other and an urging connection portion 36 continued from a pair of the contact pieces 35, and urging the pair of the contact pieces 35 between which the electrical contact portions 8 and 27 are sandwiched, in a direction to approach each other. The clip terminal is caused to approach the electrical contact portions 8 and 27 along a crossing direction with respect to the longitudinal direction of the electrical contact portions 8 and 27 superimposed on each other, and sandwiches the electrical contact portions 8 and 27 superimposed on each other, between a pair of the contact pieces 35.