Terminal Fitting with Offset Crimping and Cutouts
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Solution Overview
Problem
Existing terminal fittings face reduced connection reliability due to deformation of the welding portion during crimping, as the crimping and welding portions are connected via side walls, leading to potential disconnection of wire cores.
Innovation Solution
A terminal fitting design with offset crimping pieces and cutouts at the upper ends of the side walls, preventing deformation forces from affecting the welding portion, ensuring connection reliability and preventing wire disconnection, along with an L-shaped holding piece for secure mounting and preventing entanglement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the crimping portion and welding portion are connected integrally via side walls, then the terminal fitting structure is simple and strong, but the welding portion may be deformed during crimping, reducing connection reliability
Solution Approach 1:
The side wall is divided into two distinct portions: a first side wall portion connecting the welding portion to the bottom wall, and a second side wall portion connecting the crimping portion to the bottom wall. These portions are positioned at different locations and can deform independently during crimping, preventing deformation transmission to the welding portion while maintaining overall structural integrity.
2Reliability
If cutouts are formed at upper ends of side walls, then deformation forces are prevented from transmitting to welding portion, but the side wall structure becomes more complex
Solution Approach 1:
Cutouts are formed at the upper ends of the side walls to extract and isolate the deformation-prone regions. These cutouts allow the side wall portions to deform independently during crimping without transmitting forces to the welding portion, while the remaining side wall structure maintains sufficient mechanical strength.
3Ease of operation
If the holding piece extension length is larger than insertion hole diameter, then terminal fittings can be easily separated, but the holding piece design becomes more complex
Solution Approach 1:
The holding piece is designed with an asymmetric L-shaped cross section where the extension length in the forward-backward direction exceeds the insertion hole diameter, while the width in the lateral direction is smaller. This asymmetric geometry allows easy separation by pulling in the forward-backward direction while preventing entanglement, without requiring complex mechanisms.
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
Enhances connection reliability by isolating deformation forces from the welding portion and provides secure mounting and easy separation of terminal fittings through the L-shaped holding piece, reducing the risk of wire disconnection and entanglement.
Implementation Method 1
Cores of wires are welded (thermocompression bonded) to the bottom wall at the welding portion
Data Source
AI summary
A terminal fitting (10) includes a terminal main body (21) with a bottom wall (22) on which cores (71) of wires (70) are placed, and two side walls (23) that stand up from opposite lateral sides of the bottom wall (22). A welding portion (25) where the cores (71) are welded to the bottom wall (22) is formed at a front part of the terminal main body (21). A crimping portion (26) is formed at a rear part of the terminal main body (21) and has crimping pieces (27) projecting from upper ends of the side walls (23) for crimped connection to the wires (70). Cutouts (28AF, 28AR) are cut into the upper end of the side wall (23) of the crimping portion (26) at front and rear sides of the front crimping piece (27F) while retaining parts of the side wall (23L) below the cutouts (28AF, 28AR).