Crimp Terminal Body Notch Structure for Crack-Free Connector Mating
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Solution Overview
Problem
High-voltage connectors experience cracks at the corner between the side wing and connecting part of the terminal body during crimping, leading to changes in the insertion gap size, affecting the mating terminal's insertion.
Innovation Solution
A stress relief notch is formed at the corner between the side wing and connecting part of the terminal body, reducing local stress concentration and preventing cracks, while maintaining the contact area with the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If an arc shaped chamfer is formed at the corner between the side wing and connecting part, then the terminal body structure is simplified, but cracks appear at the corner during crimping
Solution Approach 1:
The patent applies local quality by creating a stress relief notch specifically at the corner position where stress concentration occurs during crimping. This localized structural modification concentrates the stress relief function at the critical corner area without changing the overall terminal body structure, thereby preventing cracks while maintaining structural simplicity.
2Reliability
If the corner structure is modified to prevent cracks, then reliability is improved, but the insertion gap size may change
Solution Approach 1:
The stress relief notch is designed with specific dimensional constraints (depth and width) to ensure it only affects the local stress distribution at the corner without propagating to the mating part. This localized approach prevents cracks while maintaining the insertion gap dimensions within acceptable tolerances.
Solution Approach 2:
The patent specifies precise parameters for the stress relief notch including depth (0.5-2mm) and width (1-3mm) to optimize the balance between stress relief effectiveness and maintaining the insertion gap size. By controlling these parameters, the design achieves crack prevention without significantly affecting the mating part's insertion characteristics.
Data Source
AI summary
A terminal body includes a crimping part adapted to be crimped onto a cable, a mating part adapted to mate with a mating terminal, and a connecting part connected between the crimping part and the mating part. The crimping part includes a base connected to the connecting part and a pair of side wings extending from a pair of sides of the base beyond the connecting part. A stress relief notch is formed at a corner between each of the side wings and one of the connecting parts.