Stress-Absorbing Terminal Fitting for Thermal Expansion Reliability
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Solution Overview
Problem
Stress generated in terminal fittings due to ambient temperature variations can lead to breakage or connection failures.
Innovation Solution
A terminal fitting design with a detached-side terminal portion, a mounting-side terminal portion, and a stress absorbing portion arranged between them, featuring resilient deformation to relax stress, enhanced rigidity through reinforcement plates, and obtuse angles to reduce material cost and prevent stress concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a terminal fitting is made with a linear arrangement of terminal portions and linking portion, then the structure is simple and easy to manufacture, but stress generated by thermal expansion or contraction can cause breakage or connection failure
Solution Approach 1:
The terminal fitting is divided into three functional segments: a detached-side terminal portion, a mounting-side terminal portion, and a stress absorbing portion. This segmentation allows the stress absorbing portion to specifically handle thermal expansion stress while the other portions maintain their respective functions, resolving the contradiction between structural simplicity and connection reliability.
Solution Approach 2:
The stress absorbing portion changes the physical parameters of the terminal fitting by introducing a region with different mechanical properties (lower rigidity, higher flexibility). This parameter change allows the fitting to accommodate thermal expansion without breaking, while maintaining overall structural simplicity for ease of manufacture.
2Strength
If the stress absorbing portion is connected at right angles or acute angles, then the structural rigidity is higher, but stress concentrates at the bent parts causing breakage
Solution Approach 1:
The stress absorbing portion uses obtuse angles instead of the conventional right angles or acute angles. This asymmetric angular design distributes stress more evenly along the bent parts, preventing stress concentration and reducing the likelihood of breakage while maintaining sufficient structural rigidity.
Solution Approach 2:
The bent parts of the stress absorbing portion, which would normally be weak points prone to breakage, are converted into beneficial stress-distributing elements. The obtuse angles transform potential stress concentration zones into stress-dispersing regions, turning a harmful structural feature into a beneficial one.
3Strength
If reinforcement plates are added to enhance rigidity, then the structural strength is improved, but the material cost and manufacturing complexity increase
Solution Approach 1:
The reinforcement plates are merged with the stress absorbing portion in an integral structure, eliminating the need for separate assembly steps. This combining of components maintains the rigidity enhancement benefit while reducing manufacturing complexity by treating the reinforcement plates and stress absorbing portion as a single molded piece.
Solution Approach 2:
The reinforcement plates serve multiple functions: they enhance the rigidity of the terminal portions, provide structural support, and maintain the overall shape of the terminal fitting. This multi-functionality reduces the need for additional components, thereby controlling manufacturing complexity while achieving the desired strength improvement.
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 effectively relaxes stress in the terminal fitting, reduces material cost, and prevents breakage by distributing stress uniformly, ensuring stable connections.
Implementation Method 1
a stress absorbing portion arranged between the detached-side terminal portion and the mounting-side terminal portion
Implementation Method 2
stress generated in a terminal fitting can be relaxed
Data Source
AI summary
A terminal fitting (10) includes a detached-side terminal portion (12) to be connected to a mating terminal (T), a mounting-side terminal portion (11) to be mounted on a circuit board (P) and a stress absorbing portion (18) arranged between the detached-side terminal portion (12) and the mounting-side terminal portion (11). Stress generated in the detached-side terminal portion (12) and the mounting-side terminal portion (11), out of the terminal fitting (10), can be relaxed by the resilient deformation of the stress absorbing portion (18).