Electrical Terminal Push Surface for Insertion Ease
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Solution Overview
Problem
Existing flag terminals have a small, difficult-to-access bearing surface with sharp edges, making it challenging to insert them into connector housings and mate with mating terminals, which can lead to assembler injuries and damage.
Innovation Solution
An electrical terminal with a contact portion, wire termination portion, and transition portion, featuring an engagement section with a push surface that intersects the mating axis, providing an ergonomically friendly surface for easy insertion and mating without the need for special tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the bearing surface is made small to save space, then the terminal can fit into smaller spaces, but the insertion becomes difficult and may cause injuries
Solution Approach 1:
The patent extends the bearing surface along the mating axis (adding a dimensional element) rather than expanding it laterally. This creates a protruding push surface that increases the effective insertion area without increasing the terminal's lateral footprint, resolving the contradiction between compact size and ease of insertion
Solution Approach 2:
The protruding push surface is positioned to make initial contact with the mating terminal or connector housing during insertion. This preliminary contact point allows the assembler to apply force before the main body of the terminal engages, facilitating easier and safer insertion
2Strength
If the bearing surface has sharp edges to maintain structural integrity, then the terminal strength is maintained, but the assembler may be injured
Solution Approach 1:
The patent applies different surface qualities to different parts of the terminal. The main body retains sharp edges for structural integrity, while the protruding push surface has a rounded or chamfered leading edge that is safe for assembler contact. This local differentiation resolves the contradiction between strength and safety
Solution Approach 2:
The protruding push surface acts as an intermediary element between the assembler's finger and the main terminal body. It transfers the insertion force while protecting the assembler from direct contact with sharp edges on the main terminal structure
3Ease of operation
If a larger bearing surface is provided to ease insertion, then the ease of operation improves, but the terminal size increases
Solution Approach 1:
Instead of expanding the bearing surface in lateral dimensions (which would increase terminal size), the patent extends it along the mating axis. This dimensional reorientation provides a larger effective insertion surface without increasing the terminal's footprint in other dimensions
Data Source
AI summary
An electrical terminal having a contact portion, a wire termination portion and a transition portion. The contact portion is configured to receive a mating terminal along a mating axis. The wire termination portion defines a wire termination axis that intersects the mating axis. The transition portion extends between the contact portion and the wire termination portion. The transition portion extends parallel to the mating axis and the wire termination axis. An engagement section extends at an angle from the transition portion. The engagement section has a push surface intersecting the mating axis. Wherein a force can be applied to the push surface to mate the contact portion with the mating terminal.