Terminal Wire Reinforcement to Prevent Buckling During Sealed Insertion
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Solution Overview
Problem
The increasing smaller diameter of wires makes them more prone to buckling during insertion into terminal mounting holes, and the addition of a sealing member increases frictional forces, complicating assembly and sealability.
Innovation Solution
A wire with terminal that includes a reinforcing material applied to the outer surface of the insulation coating, extending from the rear end of the sealing member into the terminal mounting hole, which suppresses buckling while maintaining sealability by ensuring intimate contact between the sealing member and insulation coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealing member is attached to the outer periphery of the wire, then sealability of the terminal mounting hole is improved, but frictional force between the terminal mounting hole and the sealing member increases, making the wire more likely to buckle during insertion
Solution Approach 1:
A reinforcing material is introduced as an intermediary component between the wire and the sealing member. This reinforcing material extends along the wire's outer periphery and provides structural support to the wire, preventing buckling during insertion while allowing the sealing member to maintain intimate contact with the wire for effective sealing.
Solution Approach 2:
The wire structure is transformed into a composite construction by attaching a sealing member and a reinforcing material to the wire's outer periphery. The reinforcing material acts as a structural enhancement layer that prevents buckling, while the sealing member provides sealing functionality, creating a multi-functional composite structure.
2Length of moving object
If the wire diameter is reduced, then the wire becomes more flexible and easier to route, but the wire becomes more prone to buckling during insertion into the terminal mounting hole
Solution Approach 1:
The wire is enhanced by attaching a reinforcing material to its outer periphery, creating a composite structure. This reinforcing material provides structural support and prevents buckling during insertion, allowing the use of smaller diameter wires that would otherwise be too flexible and prone to buckling.
Solution Approach 2:
The wire structure is segmented into the core wire and the attached reinforcing material. The reinforcing material acts as a separate structural element that provides buckling resistance while allowing the core wire to maintain its small diameter for flexibility and routing ease.
Data Source
AI summary
The present disclosure suppresses, in a wire with terminal provided with a sealing member, buckling of a wire during insertion into a terminal mounting hole. A wire with terminal includes a wire having a core wire made of a conductor and an insulation coating covering the outer periphery of the core wire, a terminal connected to a lengthwise end portion of the wire, a tubular sealing member enclosing the outer periphery of the insulation coating, and a reinforcing material adhered to the outer peripheral surface of the insulation coating. The lengthwise end portion of the wire with terminal including the terminal and the sealing member is inserted into a terminal mounting hole of a housing. Also, the reinforcing material is provided in an area extending rearward from a rear end portion of the sealing member in an insertion direction into the terminal mounting hole.