Terminal Fitting Connection Structure for Multiple Grounding Wires
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Solution Overview
Problem
Existing terminal fitting connection structures face challenges with increased weight, space requirements, and reliability issues when connecting multiple grounding electric wires, particularly due to the need for stacking and the use of bolts, which can lead to loose connections and variations in crimping strength.
Innovation Solution
A connection structure for terminal fittings that uses caulked fastening pieces and an engagement mechanism, such as concave-convex engagement portions or protruding portions, to securely connect multiple electric wires without stacking, eliminating the need for bolts and holding mechanisms, allowing for easy adaptation to varying wire sizes and numbers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If terminal fittings are stacked and fastened with bolts to connect multiple grounding electric wires, then multiple wires can be connected in a lump, but weight increases and space requirements increase
Solution Approach 1:
The patent merges multiple terminal fittings into a single integrated terminal fitting structure that can accommodate and connect multiple grounding electric wires simultaneously. The terminal fitting includes a base plate with multiple connection portions extending in different directions, allowing multiple wires to be connected without stacking separate fittings, thereby reducing overall weight while maintaining the ability to connect multiple wires in a lump.
2Adaptability or versatility
If terminal fittings are stacked and fastened with bolts to connect multiple grounding electric wires, then multiple wires can be connected in a lump, but the thickness increases requiring more space
Solution Approach 1:
Instead of stacking terminal fittings in the thickness direction (vertical stacking), the patent extends connection portions in the planar direction (horizontal extension) from the base plate. This dimensional change allows multiple grounding electric wires to be connected without increasing the thickness of the assembly, as connection portions extend radially outward from the base plate rather than stacking vertically.
3Adaptability or versatility
If bolts are used to fasten terminal fittings, then multiple grounding electric wires can be connected, but the connection reliability deteriorates after fastening due to loosening
Solution Approach 1:
The patent replaces the mechanical bolt fastening system with a deformation-based mechanical interlocking system. Connection portions are deformed to wrap around and interlock with the grounding electric wires, creating a friction-based hold that prevents loosening. This substitution eliminates the reliability issues associated with bolt loosening while maintaining the ability to connect multiple grounding electric wires.
4Adaptability or versatility
If a joint connector with holding mechanism is used to connect multiple grounding electric wires, then wires can be connected in a lump, but the housing cannot be miniaturized and cost increases
Solution Approach 1:
The patent extracts and eliminates the complex holding mechanism (such as lock lances and housing structures) from the connection system. Instead, the terminal fitting uses simple deformation of connection portions to achieve mechanical interlocking with grounding electric wires. This extraction of unnecessary components simplifies the overall structure, enables miniaturization, and reduces cost while maintaining the ability to connect multiple wires in a lump.
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 solution provides a reliable, space-efficient, and cost-effective method for connecting multiple electric wires by preventing detachment and stabilizing the connection process, reducing weight and cost, while allowing for flexible handling of different wire sizes and quantities.
Implementation Method 1
the pair of fastening caulking pieces are caulked with opposite side portions of a corresponding one of the terminal connection portions from outside so as to roll up the opposite side portions so that the connection terminal is caulked and fastened to the terminal fitting
Implementation Method 2
the terminal connection portion and the connection terminal include an engagement mechanism that prevents the terminal connection portion from detaching from the fastening caulking pieces
Data Source
AI summary
A connection structure for a terminal fitting includes the terminal fitting including a terminal body and a plurality of terminal connection portions extending from the terminal body, and connection terminals connected to electric wires. Each of the connection terminals include a pair of fastening caulking pieces. The pair of fastening caulking pieces are caulked with opposite side portions of a corresponding one of the terminal connection portions from outside so as to roll up the opposite side portions so that the connection terminal is caulked and fastened to the terminal fitting. The terminal connection portion and the connection terminal include an engagement mechanism that prevents the terminal connection portion from detaching from the fastening caulking pieces. The terminal fitting is connected to the electric wires through the connection terminals.