Terminal Fixation Structure Positioning Ribs Resin Reduction

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Solution Overview

Problem

The existing terminal fixation structure for power supply devices in hybrid and electric vehicles has large dimensional tolerances, leading to imprecise positioning of connection terminals with respect to terminal fixing portions, which can result in assembly errors and inefficiencies.

Innovation Solution

The terminal fixation structure features positioning ribs extending from the terminal insertion starting to ending position on the terminal fixing portion, with matching positioning recessed portions on the connection terminal, allowing precise alignment and reduced resin usage by minimizing the installation area of the terminal placement plate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If large fit dimensions are used for positioning ribs and terminals, then manufacturing is easier with larger tolerances, but positioning precision deteriorates leading to assembly errors

Engineering Contradiction:

Improveease of manufactureVSAvoidpositioning precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent transitions from using longitudinal dimensions (length of positioning ribs) for positioning to using width dimensions (width of positioning ribs and recessed portions) for positioning. This dimensional change allows for smaller fit dimensions and tighter tolerances in the width direction, thereby improving positioning precision while maintaining manufacturability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent changes the critical fit dimension from the longitudinal direction to the width direction of the positioning ribs. By making the width of the positioning ribs and the width of the positioning recessed portions the determining factors for positioning accuracy, the patent enables tighter tolerances and more precise assembly.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If terminal placement plate covers entire terminal housing chamber, then positioning accuracy is improved, but resin usage increases

Engineering Contradiction:

Improvepositioning accuracyVSAvoidresin usage

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent segments the terminal placement plate into a localized structure positioned only at the center of the terminal housing chamber, rather than using a continuous plate covering the entire chamber. This segmentation maintains positioning accuracy at the critical terminal location while reducing the amount of resin material required.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies the terminal placement plate locally only where needed (at the center of the terminal housing chamber) rather than uniformly across the entire chamber. This local quality approach provides positioning support exactly where terminals are inserted while minimizing unnecessary resin usage in other areas.

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP2807689B1Terminal fixation structure and power supply device using the same

Publication Date: 2018.10.10 YAZAKI CORP

Figure 1
Figure 2
Figure 3(a)~3(b)

AI summary

A terminal fixation structure includes a terminal fixing portion (13) including a terminal housing chamber (40), a terminal (30) including a positioning recessed portion (30b) and housed in the terminal housing chamber (40), and a positioning rib (41) provided in a center of the terminal fixing portion (13) to protrude into the terminal housing chamber (40) and fitted into the positioning recessed portion (30b).