Terminal Connection Structure for Offset Accommodation
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Solution Overview
Problem
Conventional terminal connection structures for high-current power devices, such as hybrid and electric vehicles, are limited in accommodating significant positional offsets between terminal fixtures, leading to potential disconnection issues due to the elastically deformed coupling pieces.
Innovation Solution
A terminal connection structure featuring a base with a movable attachment section and a press fixing member, along with a clip terminal that includes bias coupling pieces to securely hold and align terminal fixtures, allowing for greater positional flexibility and reliable electrical connection even with parallel and offset configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a thin flexible coupling piece is used to connect terminal fixtures, then small positional offsets can be accommodated through elastic deformation, but the structure cannot handle great positional offsets and may prevent movement of the inner tubular section
Solution Approach 1:
The coupling piece is divided into multiple sections: a first coupling piece with high flexibility for elastic deformation, and a second coupling piece with low flexibility for structural stability. This segmentation allows the system to accommodate great positional offsets while maintaining connection reliability.
Solution Approach 2:
The invention changes the flexibility parameter of the coupling piece by using different materials or structures for different sections. The first coupling piece uses a flexible material to allow elastic deformation, while the second coupling piece uses a rigid material to provide stable support and prevent unwanted movement.
2Stability of the object's composition
If the terminal holder is fixed rigidly to the base, then structural stability is improved, but the terminal fixtures cannot accommodate positional offsets
Solution Approach 1:
The coupling structure is segmented into flexible and rigid sections. The first coupling piece provides flexibility for positional adjustment, while the second coupling piece provides rigid structural stability. This segmentation resolves the contradiction between stability and adaptability.
Solution Approach 2:
The coupling piece transitions from a static rigid structure to a dynamic structure that can adapt its flexibility based on the connection needs. The first coupling piece allows dynamic elastic deformation to accommodate positional offsets, while the second coupling piece maintains static rigidity for stability.
3Ease of operation
If the coupling piece is made thin and flexible for small offsets, then ease of connection is improved, but the structure width cannot be reduced and disconnection risks increase for great offsets
Solution Approach 1:
The coupling system is segmented into two functional parts: the first coupling piece that is thin and flexible for easy connection through elastic deformation, and the second coupling piece that provides structural support to prevent disconnection. This segmentation allows both ease of connection and high reliability.
Solution Approach 2:
The first coupling piece acts as an intermediary element that absorbs positional mismatches through elastic deformation, while the second coupling piece serves as a mediator that maintains the structural integrity and prevents complete disconnection. Together they resolve the contradiction between ease of connection and reliability.
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
The solution enables reliable and secure connections between terminal fixtures with significant positional offsets, reducing the structure's width and preventing unexpected disconnections, while ensuring stable electrical contact and easy assembly.
Implementation Method 1
a bias coupling section continued to the pair of contact pieces and biasing the pair of contact pieces holding the first and second terminal fixtures therebetween toward a direction close to each other
Data Source
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AI summary
[Problem] To provide a terminal connection structure that can reliably connect terminal fixtures together even if the positional offset between the terminal fixtures is great. [Solution] The terminal connection structure (1) connects a busbar (4) and a first terminal fixture (3) connected to the coil of a motor. The terminal connection structure (1) is provided with: a base (11) having a bottom wall (16); a terminal holder (12) that can hold the first terminal fixture (3) and the busbar (4) in an overlapping state; and a mobile attachment section (13). The mobile attachment section (13) has: a bottom plate section (22) that is provided to the terminal holder (12) and that is parallel to the bottom wall (16); and a holding slit (29) that is provided to the base (11), is entered by the bottom plate section (22), and is larger than the bottom plate section (22). The mobile attachment section (13) attaches the terminal holder (12) to the base (11) movably in parallel to the surface of the bottom wall (16).