Electrical Terminal Assembly Sealing and Retention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical terminals in devices face challenges with environmental sealing, retention, and electrical insulation, especially in adverse conditions and compact constructions, where moisture ingress and electrical shorts can occur due to conductive components contacting housings, requiring complex and labor-intensive insulation arrangements.
Innovation Solution
An electrical terminal assembly comprising terminals, terminal seals, and terminal retainers that securely engage terminal heads, resist moisture and contaminants, and prevent rotation, using a shank and seal configuration to provide environmental sealing and electrical insulation without additional tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical terminals are used in compact constructions with conductive housings, then electrical connection is achieved, but electrical shorts or failure conditions occur due to conductive portions contacting the housing
Solution Approach 1:
The patent introduces an electrically insulative retainer as an intermediary component between the conductive terminal head and the conductive housing. This retainer mechanically secures the terminal while electrically insulating it from the housing, preventing short-circuits without compromising the electrical connection function.
Solution Approach 2:
The terminal assembly is segmented into distinct functional components: the conductive terminal shank for electrical connection, the insulative retainer for mechanical retention and electrical insulation, and the seal for environmental protection. This segmentation allows each component to perform its specific function without interfering with others.
2Reliability
If environmental sealing is added to protect terminals from moisture and contaminants, then protection is improved, but device complexity and assembly labor increase
Solution Approach 1:
The patent merges multiple functions into the terminal retainer component: it provides mechanical retention of the terminal, electrical insulation from the housing, and serves as a mounting surface for the environmental seal. This consolidation reduces the number of separate components and simplifies assembly.
Solution Approach 2:
The retainer is designed as a multi-functional component that simultaneously achieves mechanical retention, electrical insulation, and seal mounting. This universal design eliminates the need for separate retainers, insulators, and seal brackets, reducing overall device complexity.
3Ease of operation
If terminals are allowed to rotate freely for easy installation, then ease of installation is improved, but stable positioning is lost making electrical connection unreliable
Solution Approach 1:
The retainer features an asymmetric recess with specific geometric constraints that match the terminal head shape. This asymmetric design allows the terminal to be inserted in the correct orientation and prevents rotation, ensuring stable positioning while maintaining ease of installation through a simple snap-fit mechanism.
Data Source
AI summary
An electrical terminal assembly includes at least one terminal, at least one terminal seal, and a terminal retainer. The terminal has a head and a shank, and the shank is configured to be received by a structure having an aperture. The terminal seal is configured to receive and engage the shank, and the shank is configured to engage the structure proximate the aperture. The terminal seal cooperates with the shank and the structure to resist ingress of contaminants into the aperture. The terminal retainer is configured to receive and selectably engage the head of the terminal and to electrically insulate the head. The terminal retainer is further configured to secure the terminal against rotation.