Conductive Terminal Sleeve Locking for Tolerance-Stable Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing conductive terminal assemblies with sleeves face issues due to sensitivity to dimensional and shape variations, leading to assembly difficulties and insufficient holding force, which affect production efficiency and cost.
Innovation Solution
A conductive terminal assembly with a locking structure featuring a protrusion or clip that engages with the sleeve and insertion portion, reducing interference sensitivity and enhancing the holding force, while allowing for integrated stamping and assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If surface interference fit is used between sleeve and conductive terminal, then holding force is provided, but assembly difficulty increases and holding force becomes insufficient due to sensitivity to dimensional and shape variations
Solution Approach 1:
The locking structure is divided into a protrusion portion on one component and a groove portion on the other component. This segmentation transforms the continuous surface interference fit into discrete localized engagement points, reducing sensitivity to dimensional variations and facilitating easier assembly while maintaining holding force.
Solution Approach 2:
Instead of relying on uniform surface interference along the entire contact surface, the locking structure concentrates the holding function at specific localized regions through the protrusion-groove engagement. This local quality approach reduces the impact of dimensional variations across the entire surface while ensuring sufficient holding force at critical engagement points.
2Strength
If surface interference fit is used between sleeve and conductive terminal, then holding force is provided, but manufacturing cost increases due to assembly difficulties
Solution Approach 1:
By segmenting the locking interface into discrete protrusion and groove features rather than relying on precise surface interference fit, the manufacturing process becomes less sensitive to dimensional tolerances. This reduces scrap rates, rework, and assembly adjustments needed, thereby lowering manufacturing costs while maintaining holding force.
Solution Approach 2:
The localized protrusion-groove locking structure concentrates the functional requirement at specific points rather than demanding precision across the entire surface. This local quality approach simplifies manufacturing by reducing the number of critical tolerance zones, lowering production costs while ensuring adequate holding force.
3Reliability
If surface interference fit is used between sleeve and conductive terminal, then connection is provided, but reliability decreases due to sensitivity to dimensional and shape variations
Solution Approach 1:
Segmenting the connection interface into discrete protrusion and groove features creates defined engagement points that are less sensitive to overall dimensional variations. The localized nature of these features ensures reliable locking even when general dimensional tolerances vary within acceptable ranges, improving connection reliability.
Solution Approach 2:
By implementing the locking function through localized protrusion-groove features rather than relying on uniform surface interference, the connection reliability becomes dependent on the precision of these localized features rather than the entire surface. This local quality approach reduces sensitivity to dimensional variations and shape deviations, enhancing overall connection reliability.
Data Source
AI summary
A conductive terminal assembly includes a conductive terminal, a sleeve, and a locking structure. The conductive terminal has an end with an insertion portion. The insertion portion has an insertion cavity receiving a mating terminal. The sleeve is sleeved on an outside of the insertion portion. The locking structure fixes the sleeve and the insertion portion together. The locking structure has a protrusion protruding from one of a side wall of the insertion portion and a side wall of the sleeve towards the other. The protrusion is engaged with another of the side wall of the insertion portion and the side wall of the sleeve to suppress a movement of the sleeve relative to the insertion portion.