Terminal Lug Spacer for Multi-Wire Alignment and Assembly

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Solution Overview

Problem

Existing methods for securing multiple wires in a terminal lug are complex and often require forcing wires into a barrel, leading to assembly difficulties and undesirable exposure of un-insulated wire sections.

Innovation Solution

A spacer or insert is used within the terminal lug to align and position multiple wires, simplifying assembly by creating defined spaces for wire placement and ensuring secure capture upon crimping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If multiple wires are forced into the barrel without a spacer, then the assembly process becomes complex and difficult, but the wires can be secured in the terminal lug

Engineering Contradiction:

Improveease of wire assemblyVSAvoidassembly complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

A spacer is introduced as an intermediary component between the wires and the barrel. The spacer has a body with multiple cavities that receive and position the wires, and protrusions that engage with the barrel to secure the assembly. This intermediary element simplifies the assembly process by providing a structured framework for wire placement and securing, eliminating the need to force wires directly into the barrel.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If wires are secured without a spacer, then the assembly may be simpler, but un-insulated sections of wire extend away from the barrel which is undesirable

Engineering Contradiction:

Improvewire insulation coverageVSAvoidassembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The spacer acts as a mediator that ensures proper wire positioning and insulation coverage. The cavities in the spacer body are sized to accommodate the insulated portions of the wires, while the protrusions extend into the barrel to secure the wires. This structure prevents un-insulated wire sections from extending away from the barrel, thereby improving reliability without excessive complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If a spacer is added to align and position wires, then assembly is simplified and wire positioning is improved, but the device structure becomes more complex

Engineering Contradiction:

Improvewire alignment precisionVSAvoidterminal lug structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The spacer is segmented into distinct functional elements: a body with multiple cavities for receiving individual wires, and protrusions for engaging with the barrel. Each cavity is specifically shaped and sized to accommodate a wire, providing precise alignment and positioning. This segmentation allows for improved manufacturing precision in wire placement while keeping the overall structure manageable through modular design.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS7601037B2Terminal with multiple wire connection

Publication Date: 2009.10.13 HAMILTON SUNDSTRAND CORP

AI summary

An electrical connection for securing multiple wires within an interior of an electrical connector barrel includes the use of a spacer which is received within the barrel, and which includes guiding spaces to position the plurality of wires.