Terminal Fitting Connection Structure Using Nested Caulking
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Solution Overview
Problem
Existing connection structures for terminal fittings require significant space and weight as the number of grounding wires increases, and the reliability of the connection can be compromised due to loose bolts and fluctuations in crimping strength.
Innovation Solution
A provisional engaging structure and method for terminal fittings and connection terminals, utilizing fastening caulking pieces and caulked pieces with a provisional engaging mechanism, allowing for detachable engagement and stable crimping, which reduces the need for stacking and enhances connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal fittings are stacked and fastened with bolts to connect multiple grounding wires, then connection reliability is improved, but weight increases and space requirements increase
Solution Approach 1:
The invention divides the connection structure into two independent parts: terminal fittings connected to grounding wires, and connection terminals connected to electric wires. These segmented parts are joined through crimping rather than stacking, eliminating the need to increase the number of stacked terminal fittings as the number of wires increases.
Solution Approach 2:
The connection terminal is inserted into and nested within the terminal fitting, with the caulked pieces of the terminal fitting accommodating the fastening caulking pieces of the connection terminal. This nested structure allows multiple connections without increasing overall weight or space requirements.
2Adaptability or versatility
If terminal fittings are stacked to connect more grounding wires, then connection capability is improved, but thickness and space requirements increase
Solution Approach 1:
The invention segments the connection function into terminal fittings for grounding wire attachment and connection terminals for electric wire attachment. This eliminates the need to stack terminal fittings to increase connection capability, thereby controlling thickness.
Solution Approach 2:
Instead of increasing connection capability by stacking in the thickness direction (one dimension), the invention adds connection terminals in the planar direction (another dimension), allowing multiple electric wires to be connected without increasing thickness.
3Reliability
If connection terminals are crimped to terminal fittings to prevent bolt loosening, then connection reliability is improved, but positional stability during crimping deteriorates
Solution Approach 1:
The invention performs preliminary positioning by inserting the connection terminal into the terminal fitting before crimping. The caulked pieces and fastening caulking pieces are preliminarily engaged to establish stable relative postures, ensuring precise crimping without positional displacement.
Solution Approach 2:
The caulked pieces and fastening caulking pieces serve as intermediary elements that mediate the connection between the terminal fitting and connection terminal. These intermediaries provide stable engagement and positioning during the crimping process, ensuring manufacturing precision.
4Adaptability or versatility
If multiple terminal fittings are stacked and fastened, then more grounding wires can be connected, but work time increases
Solution Approach 1:
The invention segments the connection process into independent terminal fitting connections and connection terminal connections. This allows parallel processing where multiple connection terminals can be attached to their respective terminal fittings simultaneously, reducing total fastening time.
Solution Approach 2:
The invention merges the functions of terminal fitting and connection terminal into a single integrated connection structure. This combination eliminates the need for separate stacking and fastening operations for each wire, streamlining the overall fastening process.
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 enables high-reliability connection of multiple electric wires with reduced weight and space requirements, while allowing for easy assembly and correction of misconnections, and accommodating wires of varying sizes without altering the connection configuration.
Implementation Method 1
the connection terminal has a holding space defined by a pair of fastening caulking pieces provided so as to stand upright on both side sections of the connection terminal and upper end sections of the pair of fastening caulking pieces which are folded back inwardly, the pair of fastening caulking pieces being capable of caulking and fastening the connection terminal to the terminal fitting
Data Source
AI summary
A terminal fitting includes a terminal body and a plurality of terminal connection sections. A connection terminal is connected to an electric wire. The connection terminal has a holding space defined by a pair of fastening caulking pieces provided on both side sections of the connection terminal and upper end sections of the pair of fastening caulking pieces which are folded back inwardly. A pair of caulked pieces is provided so as to stand upright on both side sections of the terminal connection section and is configured to be accommodated in the holding space. A provisional engaging mechanism that is detachably engaged with the pair of fastening caulking pieces when the pair of caulked pieces is accommodated in the holding space and is provided between the pair of caulked pieces and the pair of fastening caulking pieces.