Terminal Module Walls That Prevent Rotation and Contact Wear
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Solution Overview
Problem
Existing terminal configurations allow for backlash and rotation displacement between male and female terminals, particularly when large-diameter electric wires are connected, leading to potential wear of the connection portion due to vehicle vibrations.
Innovation Solution
A terminal module with a flat plate metal fitting and an elastic member that includes an electric wire fixing section, a rectangular connection section, and a pair of displacement-restricting walls to prevent rotation around an axis, using a separate elastic member to stabilize the connection and reduce wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large-diameter electric wire is connected to the female terminal, then the electrical connection capability is improved, but the terminal becomes thick and heavy, causing significant vibrations and rotation displacement that lead to surface plating wear
Solution Approach 1:
The terminal body is segmented into functional zones: the connection section with displacement-restricting walls for mechanical stability, the intermediate section for elastic member engagement, and the electric wire fixing section for electrical connection. This segmentation allows each zone to address specific requirements independently, preventing rotation displacement while maintaining electrical connectivity.
Solution Approach 2:
The displacement-restricting walls are pre-configured in the terminal body to counteract rotation displacement forces before they occur. These walls create a physical barrier that prevents the terminal from rotating around its longitudinal axis, thereby protecting the surface plating from wear caused by vibrations and rotation.
2Ease of manufacture
If the terminal structure is simplified without displacement-restricting walls, then the manufacturing complexity is reduced, but rotation displacement occurs leading to surface plating wear
Solution Approach 1:
The displacement-restricting walls are added only at the connection section where rotation displacement occurs, rather than redesigning the entire terminal structure. This localized addition maintains the overall simplicity of the terminal while providing targeted protection against rotation displacement and surface plating wear.
3Reliability
If the elastic member pressing force is increased, then the connection stability is improved, but the terminal and mating terminal experience greater friction and potential damage
Solution Approach 1:
The displacement-restricting walls are pre-configured to limit rotation displacement before excessive pressing forces can cause damage. By preventing rotation early in the connection process, the walls reduce the need for excessive elastic member force, thereby protecting the surface plating from friction-induced damage while maintaining connection stability.
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 solution effectively suppresses rotation displacement at the connection point, stabilizing the connection and reducing abrasion between the terminals, even with heavy electric wires, through the use of displacement-restricting walls and an elastic member.
Implementation Method 1
an elastic member configured to press the terminal and the mating terminal against each other in the first direction
Data Source
AI summary
A terminal module according to an embodiment of the present disclosure includes a flat plate metal fitting superimposed on a mating terminal in a first direction, and an elastic member configured to press the flat plate metal fitting and the mating terminal against each other in the first direction. The flat plate metal fitting has an electric wire fixing section provided on one end side in a second direction, being a direction intersecting the first direction, and to which an electric wire is fixed, a rectangular flat plate shaped connection section provided on the other end side in the second direction and superimposed on the mating terminal, and a pair of displacement-restricting walls provided. The pair of displacement-restricting walls have a space set therebetween so as to regulate rotation around an axis along the first direction of the mating terminal arranged between the displacement-restricting walls.