Wire Terminal Slide Structure for Stronger Hold and Easy Insertion
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Solution Overview
Problem
The existing method for connecting a terminal to a wire requires large-scale facilities for crimping, leading to high manufacturing costs and difficulties in inserting the wire due to holding protrusions.
Innovation Solution
A terminal with a terminal body formed from a worked metal plate, featuring a sandwiching portion with first and second holding protrusions, and a slide member with pressurizing portions to improve wire holding force and insertion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single holding protrusion is used to hold the wire, then the structure is simple, but the wire holding force is insufficient and the wire may turn up when pulled
Solution Approach 1:
The holding protrusion is divided into two separate components: a first holding protrusion and a second holding protrusion. The first holding protrusion holds the wire at one position while the second holding protrusion holds it at another position along the extending direction. This segmentation provides multiple contact points that prevent the wire from turning up when pulled, significantly improving wire holding force without requiring complex additional mechanisms
Solution Approach 2:
The two holding protrusions are arranged at different positions along the extending direction of the wire, creating a spatial distribution that prevents rotational movement. By utilizing the longitudinal dimension of the terminal body, the design achieves enhanced wire securing through positional distribution rather than increasing the complexity of individual protrusion structures
2Ease of manufacture
If a holding protrusion with folded metal plate material is used, then manufacturing cost is reduced, but wire insertion becomes difficult and work efficiency decreases
Solution Approach 1:
The end surface of the sandwiching portion is designed with a specific curvature radius that is larger than the radius of curvature of the wire. This local geometric modification creates a smooth insertion path at the critical contact point, allowing the wire to pass easily into the terminal body without catching on the folded edges of the holding protrusions, thereby maintaining high work efficiency while using simple folded metal plate structures
Solution Approach 2:
The end surface of the sandwiching portion is designed with a curved surface having a larger radius of curvature than the wire itself. This curvature design eliminates sharp edges that could catch the wire during insertion, creating a smooth transition path that facilitates easy wire insertion while maintaining the simplicity of the folded metal plate structure
3Reliability
If large-scale facilities such as molds or jigs are used for crimping, then connection reliability is improved, but facility investment increases manufacturing cost
Solution Approach 1:
The terminal body is designed with integrated holding protrusions that are formed directly from the folded metal plate material itself, rather than requiring separate crimping tools or molds. The folded structure creates self-forming holding features that secure the wire through the geometry of the folds, eliminating the need for expensive external crimping facilities while maintaining reliable electrical connection
Solution Approach 2:
The invention replaces expensive, reusable crimping molds and jigs with a simple folded metal plate structure that achieves the same wire securing function. The holding protrusions are formed through straightforward folding operations rather than requiring precision-machined tooling, significantly reducing facility investment while providing sufficient connection reliability for the application
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
The terminal achieves improved wire holding force and enhanced work efficiency in inserting the wire, while reducing manufacturing costs by eliminating the need for large-scale facilities.
Implementation Method 1
a sandwiching portion deformable along an extending direction of a wire
Implementation Method 2
a pressurizing portion for pressing the sandwiching portion toward the wire
Data Source
AI summary
A terminal to be connected to a front end part of a wire in an extending direction is provided with a terminal body for sandwiching the wire, and a slide member slidable with respect to the terminal body along the extending direction of the wire. The terminal body is formed by a worked metal plate material and includes a sandwiching portion for sandwiching the wire. The sandwiching portion includes a first holding protrusion formed by folding the metal plate material on a side edge intersecting the extending direction of the wire, projecting toward the wire and configured to contact the wire and a second holding protrusion formed to be located forward of the first holding protrusion in the extending direction of the wire by folding the metal plate material on a side edge along the extending direction of the wire, projecting toward the wire and configured to contact the wire.