Terminal Assembly With Resilient Contact for Tolerance Absorption

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Solution Overview

Problem

The existing terminal configurations face challenges in manufacturing due to unclear whether contact parts are fixed or resilient, leading to difficulties in achieving proper contact pressure and management, as dimensional tolerance cannot be absorbed if fixed, and individual adjustments are needed if resilient.

Innovation Solution

A terminal design featuring a male terminal with a circular cross-section tab and a female terminal with a resiliently deformable contact piece and fixed connection surfaces, allowing for variable connection distances and constant opening angles, facilitating stable connection and easier manufacturing management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If fixed pieces are used as contact parts, then manufacturing management is simplified, but dimensional tolerance cannot be absorbed and proper contact pressure cannot be achieved

Engineering Contradiction:

Improvemanufacturing managementVSAvoidcontact pressure

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The contact piece is designed as a resilient component that can dynamically adjust its position and contact pressure based on dimensional variations of the male terminal. The resilient nature allows the contact piece to deform and absorb tolerance while maintaining proper contact pressure, resolving the contradiction between simplified manufacturing management and precise contact pressure control.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The contact piece's physical state is changed from fixed to resilient, allowing it to change its deformation parameter in response to dimensional variations. This parameter change enables the contact piece to adapt to different male terminal dimensions while maintaining consistent contact pressure, thus resolving the contradiction between ease of manufacture and manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If resilient pieces are used as contact parts, then dimensional tolerance can be absorbed, but individual adjustment at each contact position is required making manufacturing management difficult

Engineering Contradiction:

Improvecontact pressureVSAvoidmanufacturing management

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Multiple contact pieces are merged into a single integrated female terminal body, eliminating the need for individual adjustment of separate contact parts. The unified resilient structure absorbs dimensional tolerance across all contact positions simultaneously, simplifying manufacturing management while maintaining precise contact pressure control.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The resilient contact piece serves multiple functions simultaneously: it absorbs dimensional tolerance, maintains proper contact pressure, and provides self-adjusting capability across all contact positions. This multi-functionality eliminates the need for individual adjustment procedures, resolving the contradiction between manufacturing precision and ease of manufacture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If three-point contact is used, then connection is established, but contact state and contact pressure need individual adjustment at each position

Engineering Contradiction:

ImproveconnectionVSAvoidadjustment complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The resilient contact pieces are designed to self-adjust to the male terminal's position and dimensions automatically upon insertion. This self-service mechanism ensures reliable three-point contact without requiring manual adjustment at each contact position, reducing device complexity while maintaining connection reliability.

Inventive Principle:

Principle #25Self-service

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 stabilizes the connection by absorbing dimensional tolerance through the resilient contact piece, simplifying manufacturing and ensuring proper contact pressure, while the constant opening angles guide the tab during connection, preventing inclination and improving manufacturing management.

Implementation Method 1

a resiliently deformable resilient contact piece... a distance between the variable connection surface and the center of the connection space is variable due to deflection and deformation of the resilient contact piece

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS11909138B2Terminal assembly including flat surface formed and aligned for achieving flat contact with mating tab

Publication Date: 2024.02.20 SUMITOMO WIRING SYSTEMS LTD

AI summary

A terminal includes a male terminal and a female terminal to be connected to each other. The male terminal includes a tab having a circular cross-section. The female terminal includes a body portion having a connecting space S formed inside, the tab being arranged in the connecting space S. The body portion includes a resiliently deformable resilient contact piece and a pair of receiving portions. The resilient contact piece has a variable connection surface arranged toward a center SO of the connecting space S when viewed from a connecting direction. The pair of receiving portions are arranged on a side opposite to the resilient contact piece across the connection space S and have a pair of flat fixed connection surfaces inclined to spread toward the variable connection surface. An opening angle of the pair of fixed connection surfaces is constant in the connecting direction.