Asymmetric Crimping Element for Uniform Peeling Force
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Solution Overview
Problem
Existing methods for producing electrically conductive connections between electrical lines and components using B-crimps result in significantly different peeling forces depending on the orientation of the crimping element, leading to instability and complexity in assembly, as higher peeling forces are required when the open side faces the component.
Innovation Solution
Designing the crimping element with a cross-section resembling a number 8 and incorporating a depression on the closed side, allowing for consistent peeling forces regardless of orientation, achieved through embossing and ultrasonic welding, ensuring a stable and easy-to-assemble connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the B-crimp is applied with its open side facing the component, then higher peeling forces and more stable material connection are achieved, but the assembly process becomes more complex and orientation-sensitive
Solution Approach 1:
The crimping element is designed with an asymmetric geometry where the closed side features two spaced-apart contact surfaces similar to the open side configuration. This asymmetric design allows the closed side to also provide localized contact zones that generate high peeling forces, eliminating the need to always orient the open side toward the component while maintaining connection stability.
Solution Approach 2:
The crimping element is designed to function effectively in both orientations by equipping both the open side and closed side with contact surface configurations that can be materially connected to the component. This multi-functionality allows either side to face the component while achieving stable material connections, simplifying the assembly process.
2Ease of operation
If the B-crimp is applied with its closed side facing the component, then easier assembly is achieved, but peeling forces are significantly reduced leading to unstable connection
Solution Approach 1:
The crimping element features asymmetric contact surface distribution where the closed side incorporates two spaced-apart contact surfaces that create localized contact zones. This asymmetric configuration on the closed side enables it to generate high peeling forces comparable to the open side, making the closed side orientation equally reliable for material connection.
Solution Approach 2:
The closed side of the crimping element is designed with localized contact surfaces that concentrate the material connection to specific zones, similar to the open side configuration. This local quality enhancement ensures that regardless of which side faces the component, the connection benefits from localized stress distribution and high peeling forces.
3Reliability
If the contact zones are made smaller to localize energy and forces, then higher peeling forces are achieved, but the contact surface area for material connection is reduced
Solution Approach 1:
The contact surface of the crimping element is segmented into multiple spaced-apart contact zones rather than a single continuous surface. This segmentation localizes the energy and forces to specific regions, creating high stress concentration points that generate elevated peeling forces while maintaining adequate overall contact surface area through the distribution of multiple zones.
Solution Approach 2:
The crimping element design enhances local quality by creating specific localized contact zones with concentrated geometry. These localized regions are optimized for high stress concentration and energy localization, generating high peeling forces, while the overall contact surface area is maintained through the strategic placement of multiple such zones.
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 modified crimping element design ensures uniform peeling forces, simplifying the assembly process and maintaining a stable material connection between the crimping element and the component, regardless of orientation, thereby enhancing the reliability and ease of assembly.
Implementation Method 1
achieved through embossing and ultrasonic welding
Data Source
Figure 1
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AI summary
In order to create a method for producing an electrically conductive connection between an electrical line (102), which comprises a plurality of individual conductors (106), and an electrically conductive component (114), comprising the following method steps: - production of a crimp element (110), which encloses the individual conductors (106) in some sections, from a crimp element blank, wherein the crimp element (110) has a closed side (122) and an open side (126), on which edge regions of the crimp element (110) lie opposite each other; and materially cohesive connection of the crimp element (110) on the closed side (122) or open side (126) thereof to a contact face (142) of the component (114), said method being simple to carry out and still always resulting in a stable materially cohesive connection between the crimp element (110) and the component (114), according to the invention the crimp element (110) is produced in such a manner that the closed side (122) of the crimp element (110) has two bearing faces (148a, 148b), which are spaced apart from each other and at which the crimp element (110) can be connected in a materially cohesive manner to the contact face (142) of the component (114).