Universal Connection Terminal for Flat Cable and Conductor Assembly
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Solution Overview
Problem
The existing connection structure for conductors and flat cables in power supply devices requires terminals with different lengths, leading to increased manufacturing complexity and limited assembly order flexibility, as well as potential cable pulling issues during assembly.
Innovation Solution
A connection structure using flexible-covered flat cables with connection terminals that can be connected at any position across the conductor arrangement, featuring a conductor connection terminal part with gripping pieces and a pressure-welding cable connection terminal part, allowing for relative displacement and simultaneous pressure-welding, thus eliminating the need for multiple terminal lengths and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If terminals with different lengths are used to match core wire positions in the flat cable, then the connection precision is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies universality by designing a single standardized terminal structure that can connect to core wires at different positions along the flat cable. The terminal includes a body portion and a coupling part with a standardized structure that accommodates various core wire positions through design flexibility rather than requiring multiple terminal types. This eliminates the need for different-length terminals while maintaining precise connection capability.
2Adaptability or versatility
If terminals with different lengths are manufactured to match different core wire positions, then the adaptability is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The terminal is designed as a universal component with a standardized structure that can adapt to different core wire positions through its coupling part geometry rather than requiring multiple specialized terminal types. This single-terminal design maintains versatility while dramatically simplifying manufacturing processes and reducing the number of metal molds required.
Solution Approach 2:
The patent utilizes parameter changes by allowing the coupling part of the terminal to accommodate variations in core wire position through geometric flexibility in the coupling structure. Rather than changing the terminal length (a physical parameter), the design adjusts the coupling part's geometry to match different positions, maintaining manufacturing simplicity while achieving adaptability.
3Ease of operation
If the flat cable is connected to terminals before being connected to conductors, then the assembly flexibility is improved, but the reliability deteriorates due to cable pulling
Solution Approach 1:
The patent applies preliminary action by enabling the flat cable to be pre-connected to terminals before the final connection to conductors is completed. The terminal structure is designed to securely hold the cable in place during the assembly process, preventing cable pulling and damage. This preliminary connection step improves assembly flexibility while the terminal's secure coupling mechanism ensures reliability is maintained throughout the assembly sequence.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces manufacturing costs and complexity, enhances assembly flexibility, and improves operational efficiency by allowing the use of uniform terminal shapes and enabling easier management and assembly of conductors and flat cables.
Implementation Method 1
a cable connection terminal part provided on the other end which is connected to the corresponding core wire of the flat cable
Data Source
AI summary
In a connection structure, a conductor connection terminal part which can connect to a connection end of the conductor in any position in a direction perpendicular to the arrangement direction of the conductor and a cable connection terminal part which is connected to a core wire of a flat cable are formed on a connection terminal, and by connecting the cable connection terminal part to either one of core wires of the flat cable, a connection position of the connection end of the conductor with the conductor connection terminal part is relatively displaced.