Partitioned-Wall Terminal Module for Jig-Free Spring Assembly
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Solution Overview
Problem
The assembly workability of terminal modules is hindered by the need to open the case with a jig to attach the first terminal, as described in Patent Document 1.
Innovation Solution
The terminal module design includes a first terminal with a guided portion, first and second engaging portions, and first and second terminal receiving portions, allowing the first terminal to be attached without opening the case, and featuring parallel extending portions and inclined surfaces for smooth movement and engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the case is opened with a jig to attach the first terminal, then the first terminal can be securely attached to the case, but the assembly process becomes complicated and workability decreases
Solution Approach 1:
The side wall is divided into multiple divided wall portions (first divided wall portion, second divided wall portion, third divided wall portion) that are separated from each other. This segmentation allows the first terminal to be attached by simply placing it between the divided wall portions without requiring case opening or complex jigs, while still providing secure attachment through the divided wall structure
Solution Approach 2:
Instead of opening the case to attach the terminal from the inside, the invention inverts the approach by having the terminal attached from the outside through the divided wall portions. The first terminal is placed between the divided wall portions and engaged with engagement protrusions, eliminating the need for case opening while maintaining secure attachment
2Manufacturing precision
If the case is opened with a jig for assembly, then proper alignment and attachment can be achieved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The divided wall portions are pre-formed with engagement protrusions and grooves during case manufacturing. The first terminal is designed with corresponding engagement features that automatically align with these pre-formed structures. This preliminary preparation of engagement features eliminates the need for complex alignment operations or jigs during assembly, improving both precision and efficiency
Solution Approach 2:
The first terminal automatically aligns and attaches itself to the case by being placed between the divided wall portions. The engagement protrusions and grooves on the divided walls and terminal work together to self-align and secure the terminal without requiring external jigs or complex alignment procedures, significantly improving assembly efficiency
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 improves assembly workability, manufacturability, durability, and electrical connection efficiency by eliminating the need for case opening and ensuring smooth terminal movement and engagement.
Implementation Method 1
a resiliently deformable coil spring
Data Source
AI summary
A terminal module includes a coil spring, a case and a terminal member. The case includes a ceiling wall and a pair of side walls. The terminal member includes a first terminal. Each of the pair of side walls includes a base portion, a first divided wall portion and a second divided wall portion. The first terminal includes a first surface, a second surface, a guided portion, a first engaging portion, a second engaging portion. The first divided wall portion includes a first base portion, a first extending portion and a first terminal receiving portion. The second divided wall portion includes a second terminal receiving portion. With the first terminal located at a first position, the guided portion is arranged between the first divided wall portion and the second divided wall portion, the first and second engaging portions are engaged with the first and second terminal receiving portions, respectively.