Terminal Fitting Components Fixing via Projection Crushing
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Solution Overview
Problem
Existing terminal fitting components for motor vehicle wiring harnesses face challenges in preventing local heat generation due to differences in cross-sectional areas, leading to increased costs from complex mold designs and additional parts required for assembly.
Innovation Solution
A method of fixing first and second terminal fitting components with a flat plate configuration, where a projection from the second flat plate is inserted into a through hole of the first flat plate and crushed to form an enlarged part, securely holding the first flat plate between the enlarged part and the second flat plate, without the need for complex bending or additional parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the first electric contacting part is formed by bending to increase cross-sectional area, then heat generation is prevented, but mold complexity increases and manufacturing cost increases
Solution Approach 1:
The terminal fitting is divided into two separate components: a first terminal fitting component with the first electric contacting part, and a second terminal fitting component with the second electric contacting part. This segmentation allows each component to have uniform thickness without requiring complex bending molds, while still preventing heat generation through the area difference design.
Solution Approach 2:
The first and second terminal fitting components are combined through a fixing structure where a projection from the second component is inserted into a through hole of the first component and crushed to form an enlarged part. This merging achieves secure assembly without requiring complex molds or additional parts.
2Temperature
If the terminal fitting is composed of separate first and second terminal fitting components, then heat generation is prevented, but structure complexity increases and manufacturing cost increases
Solution Approach 1:
The separate first and second terminal fitting components are merged through a simple fixing structure consisting of a projection inserted into a through hole and crushed to form an enlarged part. This simple merging mechanism prevents heat generation while avoiding complex structures or additional parts.
Solution Approach 2:
The projection itself serves as both the connecting element and the fastening mechanism. When the projection is crushed to form the enlarged part, it automatically creates a secure interference fit within the through hole, eliminating the need for separate fasteners or complex assembly mechanisms.
3Ease of manufacture
If a rivet not formed in one piece is used to fix terminal fitting components, then assembly is achieved, but number of parts increases and manufacturing cost increases
Solution Approach 1:
The fixing structure merges the connection function and fastening function into a single integrated solution. The projection from the second terminal fitting component serves as both the connecting element and the fastening mechanism when crushed to form the enlarged part, eliminating the need for separate rivets or additional fasteners.
Solution Approach 2:
The fixing function is extracted from the terminal fitting components themselves, with the projection serving as an integrated fixing feature rather than requiring external fasteners. This extraction reduces the total number of parts while maintaining assembly capability.
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 configuration reduces costs and prevents heat generation by allowing different thicknesses for the components while ensuring secure assembly and preventing loose connections and short circuits.
Implementation Method 1
crushing an end part of the projection toward the second flat plate to form an enlarged part, thereby holding the first flat plate between the enlarged part and the second flat plate
Data Source
AI summary
A terminal fitting includes first and second terminal fitting components. The first terminal fitting component includes a first flat plate having a through hole and caulking pieces. The caulking pieces stand up from both edges in the width direction of the first flat plate. The second terminal fitting component includes a second flat plate having a projection. The projection is inserted in the through hole, an end part of the projection is crushed, and the second flat plate is caulked with the caulking pieces so that the first and second terminal fitting components are fixed to each other, thereby obtaining the terminal fitting.