Terminal Contact Structure for Stable Grip and Low Plating Scrape
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Solution Overview
Problem
The existing terminal unit design experiences issues with low gripping force against external forces, leading to increased contact resistance and potential plating scraping due to fine sliding friction and pressure changes during insertion and withdrawal of the male terminal.
Innovation Solution
A terminal unit design featuring a male terminal with inclined portions and a female terminal with separate push-up protrusions and contact points, allowing for stable connection and reduced sliding friction, thereby suppressing displacement and plating scraping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the male terminal is sandwiched by a pair of wall portions in the conventional design, then the structure is simple, but the gripping force against external forces in the plate width direction is small
Solution Approach 1:
The female terminal is divided into multiple contact portions (first contact portion and second contact portion) instead of using a single wall structure. Each contact portion has specific functions: the first contact portion provides gripping force, while the second contact portion with push-up protrusions guides insertion and provides additional contact points, thereby increasing overall gripping force without excessive complexity
Solution Approach 2:
The contact portions are arranged in different spatial dimensions and orientations. The first contact portion contacts the male terminal from one side, while the second contact portion with multiple push-up protrusions contacts from another side, creating multi-dimensional constraint that enhances gripping force in the plate width direction
2Reliability
If the male terminal rides on the contact points during press-fitting or withdrawal, then the connection is established, but the pressure increases causing plating scraping
Solution Approach 1:
The push-up protrusions on the second contact portion make contact with the male terminal before the main contact points engage during insertion. This preliminary action guides the male terminal into proper position and distributes initial pressure, preventing direct impact on the plating at the main contact points
Solution Approach 2:
The push-up protrusions act as intermediary elements between the female terminal body and the male terminal. These protrusions provide a gradual transition during insertion, mediating the force application to avoid sudden pressure spikes that would cause plating scraping at the contact points
3Reliability
If vibration occurs between the male and female terminals, then the connection is maintained, but fine sliding friction increases the contact resistance value
Solution Approach 1:
The contact portions are designed with specific geometric parameters including inclined surfaces and multiple contact points. These parameter optimizations increase the contact area and distribute vibrational forces across multiple points, reducing the impact of sliding friction on contact resistance while maintaining connection 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 design effectively suppresses displacement and plating scraping, maintaining a stable connection by utilizing reaction forces and reducing contact resistance.
Implementation Method 1
the male terminal being in contact with the push-up protrusion and pushed up toward the first contact portion, whereby the inclined portions of the male terminal are separated from the first projecting contact point portions
Implementation Method 2
a gripping force against an external force acting in a plate width direction of the male terminal is small. Thus, an increase of a contact resistance value is also conceivable due to fine sliding friction between the male and female terminals
Data Source
AI summary
In a terminal unit, a second contact portion of a female terminal includes a push-up protrusion projecting toward a first contact portion and a pair of first projecting contact point portions, to be respectively brought into contact with a pair of inclined portions, of a male terminal. The male terminal includes an accommodation recess capable of accommodating the push-up protrusion. In an incomplete connection state, the male terminal is in contact with the push-up protrusion and pushed up toward the first contact portion, whereby the inclined portions of the male terminal are separated from the first projecting contact point portions of the female terminal. In a complete connection state, the inclined portions of the male terminal are pressed by the first projecting contact point portions of the female terminal.