Terminal Orientation Feature With Coined Edge
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Solution Overview
Problem
Existing electrical terminals and connectors face challenges in multi-position applications and environmental conditions, particularly in automotive connectors, where sealing and orientation features are compromised, leading to potential damage of seals during terminal insertion and extraction.
Innovation Solution
The electrical terminal incorporates an orientation feature with a cut edge that extends beyond the body perimeter, providing a tapered and coined edge for secure alignment and minimizing seal damage during insertion and extraction, while allowing for tighter packing and larger wire accommodation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a discreet wire seal is crimped to individual contacts around individual wires, then sealing capability is improved, but the seal is damaged during terminal insertion and extraction
Solution Approach 1:
The orientation feature with the coined edge is prepared in advance on the terminal body. This pre-formed feature is designed to interact with the seal before the terminal is fully inserted, guiding the seal around the terminal and preventing direct contact between the seal and sharp edges that would cause damage during insertion and extraction operations.
Solution Approach 2:
The coined edge acts as an intermediary element between the terminal body and the seal. Instead of the seal directly contacting potentially damaging sharp edges, the coined edge serves as a mediating surface that the seal can safely engage with, thereby protecting the seal from damage while maintaining the sealing function.
2Ease of operation
If an orientation feature with a cut edge is provided on the terminal, then alignment and orientation are improved, but the seal may be cut or damaged during insertion
Solution Approach 1:
The edge of the orientation feature is coined (rounded) in advance during manufacturing. This preliminary rounding action eliminates sharp edges that would otherwise cut or damage the seal during insertion, while the orientation feature still provides the necessary alignment function.
Solution Approach 2:
The coined edge treatment is applied locally only to the specific edges of the orientation feature that contact the seal, rather than modifying the entire terminal. This localized quality change provides the necessary protection to the seal while maintaining the structural integrity and orientation function of the terminal.
3Ease of manufacture
If the orientation wall has similar thickness to body walls, then manufacturing simplicity is improved, but structural strength for seal protection may be reduced
Solution Approach 1:
The orientation wall thickness is optimized to match the body wall thickness, creating a uniform structural parameter throughout the terminal. This parameter uniformity simplifies the manufacturing process while the coined edge treatment compensates for any potential strength concerns by providing a rounded, seal-protective surface.
Data Source
AI summary
A terminal having an orientation feature that presents a cut edge in an insertion direction.