Terminal Connection Structure for Tolerance Absorption and Low Resistance
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Solution Overview
Problem
Conventional terminal connection units with elongated bolt insertion holes fail to ensure sufficient contact area between terminal fittings and connection portions, leading to high conduction resistance and heat generation issues, which can cause melting of peripheral members.
Innovation Solution
A terminal connection unit with a current-carrying member featuring a connection portion coupled to a fixing portion via an extendable portion that can extend and contract, and a support portion with a displaceable attachment portion, allowing for adjustable positioning to absorb positional tolerance without the need for elongated holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the connection portion is formed with an elongated shape and bolt insertion holes are formed as elongated holes to absorb positional tolerance, then the positional tolerance between terminal fittings and connection portion can be absorbed, but the bolt insertion holes occupy a wide range in the connection portion, making it impossible to ensure a sufficient area of contact between terminal fittings and connection portion
Solution Approach 1:
The connection portion is divided into multiple independent contact regions with individual bolt insertion holes, rather than using a single elongated hole. This segmentation allows each contact region to maintain sufficient contact area while the overall connection portion can still accommodate positional variations through the distributed arrangement of multiple contact points.
Solution Approach 2:
The bolt insertion holes are positioned within the elongated connection portion structure, with each hole surrounded by sufficient contact area. The contact regions are nested within the overall elongated geometry, allowing the connection portion to provide both the necessary contact area and the ability to absorb positional tolerance through its extended layout.
2Adaptability or versatility
If the bolt insertion holes are formed as elongated holes to allow changing fastening positions, then positional tolerance can be absorbed, but the conduction resistance at the contact location increases and heat generation becomes large
Solution Approach 1:
The connection portion is divided into multiple independent contact regions with individual bolt insertion holes, rather than using a single elongated hole. This segmentation allows each contact region to maintain sufficient contact area for low conduction resistance, while the overall elongated structure provides position adjustability.
Solution Approach 2:
Different regions of the connection portion are designed with locally optimized properties: each contact region has sufficient area for low conduction resistance, while the overall elongated structure provides position adjustability. The local contact areas are designed to minimize resistance, while the global geometry provides adaptability.
3Adaptability or versatility
If the connection portion is formed with an elongated shape to absorb positional tolerance, then positional tolerance can be absorbed, but heat generation increases due to insufficient contact area, causing melting of peripheral members
Solution Approach 1:
The connection portion is divided into multiple independent contact regions with individual bolt insertion holes, rather than using a single elongated hole. This segmentation allows each contact region to maintain sufficient contact area for low conduction resistance and reduced heat generation, while the overall elongated structure provides position adjustability.
Solution Approach 2:
Different regions of the connection portion are designed with locally optimized properties: each contact region has sufficient area for low conduction resistance and reduced heat generation, while the overall elongated structure provides position adjustability. The local contact areas are designed to minimize resistance and heat generation, while the global geometry provides adaptability.
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 effectively absorbs positional tolerance while ensuring a good connection state, reducing conduction resistance and heat generation, and preventing melting of peripheral members.
Implementation Method 1
an extendable portion that couples the connection portion and the fixing portion and is extendable and contractable in a first direction
Implementation Method 2
the attachment portion being displaceable in the first direction
Data Source
AI summary
A terminal connection unit has a novel structure that enables advantageously absorbing tolerance between positions of a terminal fitting and a connection portion while also ensuring a good state of connection between the terminal fitting and the connection portion. A terminal connection unit includes: a current-carrying member that has a connection portion for connection to a terminal fitting provided at the terminal end of an electric wire; and a support portion that fixedly supports the current-carrying member. The current-carrying member includes a fixing portion that is fixed to the support portion, and an extendable portion that couples the connection portion and the fixing portion to each other and can extend and contract in the first direction. The support portion includes an attachment portion that is attached to the connection portion and is displaceable in a first direction.