Terminal Fitting with Variable Contact Spacing for Wire Strands
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Solution Overview
Problem
Conventional terminal fittings face increased electrical resistance due to a higher number of strands in the core wire that do not make contact with the piercing part, leading to instability in the electrical connection.
Innovation Solution
A terminal fitting design featuring cantilevered side walls and pairs of press contact bodies that cut the coating of the electric wire to make contact with both the outermost and inner strands of the core wire, optimizing the contact area to reduce resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of strands in the core wire is increased, then the current carrying capacity is improved, but the number of strands that cannot contact the piercing part increases, causing increased electrical resistance
Solution Approach 1:
The core wire is segmented into multiple strands with different diameters, creating an outermost layer of larger-diameter strands and inner strands of smaller diameter. This segmentation allows the piercing part to effectively contact multiple strands simultaneously, improving electrical connection stability while maintaining high current carrying capacity.
Solution Approach 2:
Different regions of the core wire cross-section are assigned different strand diameters. The outermost layer contains strands with larger diameter to facilitate easier piercing and contact, while inner strands have smaller diameters. This local quality variation ensures that the piercing part can reliably contact strands in different regions, reducing electrical resistance.
2Device complexity
If a conventional piercing terminal design is used, then the structure is simple, but the contact area with the core wire strands is insufficient, leading to increased electrical resistance
Solution Approach 1:
The piercing part is designed with a multi-dimensional approach, featuring not only a piercing edge but also a pressing surface that extends in multiple directions. This allows the piercing part to simultaneously pierce through and press against multiple strands from different angles, increasing the effective contact area without significantly increasing overall structural complexity.
Solution Approach 2:
The piercing part is segmented into multiple contact surfaces and pressing faces that can independently contact different strands. This segmentation of the piercing part itself allows it to engage with multiple strands simultaneously, improving electrical connection reliability while maintaining a relatively simple overall structure.
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 enhances the stability of the electrical connection by increasing the contact area with the core wire, thereby reducing electrical resistance and improving connection reliability.
Implementation Method 1
configured to cut the coating of the electric wire inserted from an opening between respective free ends of the pair of side walls
Implementation Method 2
make press contact with the strands of the core wire
Data Source
AI summary
A core wire connecting body to be connected to a core wire in an electric wire includes: a bottom, a pair of cantilevered side walls that are disposed facing each other with a space therebetween; and a plurality of pairs of press contact bodies that are disposed facing each other with a space between the pair of side walls, and that cut the coating of the electric wire inserted from an opening, and make press contact with the strands. For the pairs of press contact bodies, compared to a distance between the press contact bodies that is a pair at the farthest section that is farthest from an end part of the electric wire, a distance between the press contact bodies that is a pair closer to the end part of the electric wire than the pair at the farthest section are, is smaller.