Terminal Contact Structure for Vibration-Resistant Tab Insertion
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Solution Overview
Problem
The existing terminal fitting configurations in automotive vehicles are prone to deformation and insertion issues due to external forces, which can lead to connection failures under vibration environments.
Innovation Solution
A terminal design featuring a rectangular tube portion with a resilient contact piece, a receiving portion, and a stopper mechanism that suppresses the movement of the tab and resilient piece, ensuring reliable connection by preventing deformation and proper insertion of the mating terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resilient pieces are provided to suppress tab movement, then connection reliability is improved, but the resilient contact piece may be deformed or insertion hindered by external forces
Solution Approach 1:
The stopper portion is provided in advance to prevent the harmful effect of external forces before they can cause deformation. The stopper portion protrudes into the rectangular tube portion to preliminarily counteract the inward bending of resilient pieces caused by external forces, thereby preventing both tab movement suppression failure and insertion hindrance.
Solution Approach 2:
The stopper portion acts as a cushioning element that absorbs and mitigates the impact of external forces before they can fully deform the resilient pieces. By being positioned in advance within the rectangular tube portion, it provides a buffer that prevents excessive inward bending of the resilient pieces under external loading conditions.
2Force
If resilient pieces are bent inwardly by external force, then tab movement suppression is improved, but the resilient contact piece deforms and insertion is hindered
Solution Approach 1:
The stopper portion is designed to counteract the excessive inward bending of resilient pieces before it can occur. By protruding into the rectangular tube portion, it preliminarily prevents the resilient pieces from bending too far inward, thereby maintaining both the necessary pressing force on the tab and the proper insertion clearance.
Solution Approach 2:
The stopper portion is pre-positioned within the rectangular tube portion to establish a limit on resilient piece deformation before external forces are applied. This preliminary positioning ensures that during operation, the resilient pieces can exert sufficient pressing force on the tab without deforming enough to hinder insertion.
3Reliability
If the tip part of resilient piece contacts the resilient contact piece, then tab movement is suppressed, but deformation and connection failure occur
Solution Approach 1:
The stopper portion is positioned to prevent the tip part of the resilient piece from contacting the resilient contact piece by protruding into the rectangular tube portion first. This preliminary barrier stops the harmful contact before it can cause deformation or connection failure, while still allowing the resilient piece to function properly in suppressing tab movement.
Solution Approach 2:
The stopper portion acts as an intermediary element between the resilient piece and the resilient contact piece. It mediates the interaction by preventing direct contact between these two components, thereby avoiding the harmful effects of deformation and connection failure while still maintaining the tab movement suppression 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
The solution effectively prevents deformation and ensures reliable connection between the terminal and mating terminal under vibration environments by suppressing the movement of the tab and resilient piece, thereby enhancing connection reliability and preventing wear.
Implementation Method 1
a resilient contact piece for sandwiching the tab together with the receiving portion
Implementation Method 2
a resilient piece for suppressing a movement of the tab in the first direction by pressing a side edge of the tab inwardly of the rectangular tube portion
Implementation Method 3
the rectangular tube portion including a stopper portion for suppressing a movement of a tip part of the resilient piece inwardly of the rectangular tube portion
Data Source
AI summary
A rectangular tube portion includes a first wall provided with the resilient contact piece, a second wall provided with the receiving portion and a pair of side walls connecting both side edges of the first wall and both side edges of the second wall. A facing direction of the pair of side walls is a first direction. At least one of the pair of side walls includes a resilient piece for suppressing a movement of the tab in the first direction by pressing a side edge of the tab inwardly of the rectangular tube portion 11 in the first direction. The rectangular tube portion includes a stopper portion for suppressing a movement of a tip part of the resilient piece inwardly of the rectangular tube portion in the first direction. The resilient piece includes a contact portion disposed to face the stopper portion in the first direction.