Terminal Fitting Projection Fills Cavity Clearance
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Solution Overview
Problem
Existing terminal fittings crimped with thin wires experience insertion difficulties due to clearance issues with cavity walls, leading to increased insertion resistance and potential buckling of the wire, making smooth insertion challenging, especially when inserted by hand.
Innovation Solution
A terminal fitting design featuring a tapered main portion and a wire crimping portion with a projection that fills the clearance between the crimping portion and the cavity, preventing displacement and inclining, allowing smooth insertion without gripping the wire, facilitated by a jig that pushes the projection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the terminal fitting is crimped with a thin wire, then the wire connection is compact, but the clearance between the wire crimping portion and cavity wall increases causing insertion difficulty
Solution Approach 1:
The invention introduces a projection on the wire crimping portion that locally fills the clearance between the crimping portion and cavity wall. This local structural modification ensures that thin wires maintain proper positioning during insertion without requiring the entire structure to be redesigned, thus resolving the insertion difficulty caused by excessive clearance.
Solution Approach 2:
The projection acts as an intermediary element between the wire crimping portion and the cavity wall. It mediates the clearance issue by providing contact support during insertion, preventing the terminal fitting from inclining due to the gap between thin wire crimping portion and cavity boundaries.
2Shape
If the terminal fitting inclines during insertion due to clearance, then the front end contacts the cavity ceiling, but smooth insertion is hindered by increased insertion resistance
Solution Approach 1:
The projection on the wire crimping portion provides preliminary support during insertion, preventing the terminal fitting from inclining toward the cavity ceiling. By anticipating and counteracting the inclination tendency before it causes contact with the cavity ceiling, the insertion resistance is reduced and smooth insertion is achieved.
3Ease of operation
If hand insertion is used with thin wires, then the wire must be gripped with fingers, but the thin wire buckles easily under insertion resistance
Solution Approach 1:
The projection serves as an intermediary contact point with the cavity wall during insertion, providing mechanical support that prevents wire buckling. This allows the operator to push the terminal fitting without gripping the thin wire, as the projection bears the insertion resistance force instead of the wire.
Data Source
AI summary
A terminal fitting (T) is secured to an end portion of a wire (W) and then is inserted into a cavity (11) of a housing. The terminal fitting (T) has a tubular main portion (20) for receiving a mating terminal. A wire connection portion (40) is behind the main portion (20) and can be connected with the end portion of the wire (W). At least one rounded portion (33) is provided near a front end of the main portion (20) with respect to an inserting direction (ID) of the terminal fitting (T) into the cavity (11) and at a base side of the wiring connecting portion (40).