Monolithic Terminal Insert With Touch Protection for Unshielded Connectors
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Solution Overview
Problem
Existing terminal inserts for connectors in automotive applications are complex and require multiple parts, including separate components for touch protection and shielding, which complicates assembly and increases part count, especially when connecting unshielded cables that do not need shielding.
Innovation Solution
A monolithic terminal insert with an integrated insert receptacle fitting section and touch protection section simplifies assembly by allowing unshielded cables to be connected without additional shielding, using a single piece that includes a terminal receptacle for cable terminals and optional securing elements like latching arms for secure insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-part terminal inserts are used with separate shielding parts and touch protection sections, then shielding functionality is provided, but assembly complexity increases and part count increases
Solution Approach 1:
The patent combines the touch protection section and insert receptacle fitting section into a single monolithic piece made of insulating material. This merging eliminates the need for separate shielding parts and touch protection components, reducing assembly complexity while maintaining all necessary functions including shielding when required
Solution Approach 2:
The monolithic terminal insert design provides universal functionality by integrating multiple features: touch protection, cable terminal reception, and optional shielding capabilities. The same basic structure can accommodate both shielded and unshielded cables, making the connector system more versatile without requiring different component types
2Reliability
If separate shielding parts are used for all terminal inserts, then shielding is provided, but part count increases and assembly becomes more complex
Solution Approach 1:
The patent applies shielding selectively only where needed - the monolithic piece can be configured with shielding features specifically for applications requiring it, while leaving other areas without shielding. This local quality approach reduces part count by eliminating universal shielding components while maintaining shielding functionality where required by the application
3Reliability
If multiple separate components are used for terminal insert functions, then each function can be optimized, but ease of manufacture decreases
Solution Approach 1:
By merging the touch protection section, insert receptacle fitting section, and terminal receptacle into a single monolithic piece, the patent simplifies manufacturing to a single molding or fabrication process. This eliminates the need for multiple component manufacturing and assembly operations while maintaining all necessary functional optimizations through integrated design
Data Source
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AI summary
The invention relates to a terminal insert (20) for an unshielded cable (8), the terminal insert (20) being configured to be inserted into an insert receptacle (30) of a connector (100), the terminal insert (20) comprising: an insert receptacle fitting section (23) that is adapted to be fittingly received in at least a part of the insert receptacle (30), a terminal receptacle (21) that is adapted to fittingly receive at least parts of a cable terminal (10), and a touch protection section (29) at least at a first end (91), wherein the insert receptacle fitting section (23) and the touch protection section (29) are located on one monolithic piece (99). A connector (100) comprises at least one such terminal insert (20). A set (200) comprises a connector (100), at least one such terminal insert (20) and a further terminal insert (120).