Asymmetric Flat Wire Splices for Stable Overlapping Crimping
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Solution Overview
Problem
Existing methods for connecting flat magnetic wires, such as brazing, soldering, and welding, are time-consuming, costly, and environmentally unfriendly, and standard splices are not suitable for crimping flat magnetic wires, leading to unstable connections.
Innovation Solution
The development of splices with a flat base and asymmetric or elongated tines that allow for overlapping crimping, featuring serrations to peel the coating layer and secure the wire, ensuring a stable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brazing, soldering or welding processes are used to connect flat magnetic wires, then electrical connection is achieved, but the process becomes time-consuming, costly and environmentally harmful
Solution Approach 1:
The patent replaces thermal joining processes (brazing, soldering, welding) with a mechanical crimping system. The splice structure with tines is mechanically crimped around the flat magnetic wire to establish electrical connection, eliminating the need for heating processes and achieving both reliable connection and high productivity
Solution Approach 2:
The invention extracts and eliminates the harmful thermal processes from the connection method. By using a purely mechanical crimping approach with specially designed splices, the patent removes the need for pre-stripping, heating equipment, and chemical fluxes, thereby improving productivity and environmental performance while maintaining connection reliability
2Ease of manufacture
If standard splices are used for flat magnetic wires, then the connection process is simple, but the connection stability is insufficient
Solution Approach 1:
The patent applies local quality by designing the splice with specific features tailored for flat magnetic wires: a flat base portion matching the wire's rectangular profile, and tines with serrated inner surfaces. These localized structural adaptations ensure proper fit and stable mechanical-electrical connection while keeping the overall manufacturing process simple
Solution Approach 2:
The splice structure employs asymmetry with the flat base portion and the specific configuration of tines (with serrated inner surfaces facing each other). This asymmetric design optimizes the crimping action and ensures stable connection of flat magnetic wires, while the structure remains simple to manufacture using standard stamping or drawing processes
3Reliability
If pre-stripping of wires is performed before connection, then the electrical connection can be made, but the process becomes more complex and time-consuming
Solution Approach 1:
The splice structure is pre-designed with serrated inner surfaces on the tines that will peel away the insulating coating during the crimping process itself. This preliminary design feature eliminates the need for separate pre-stripping operations, reducing process complexity and time while ensuring reliable electrical contact through the exposed conductor
Solution Approach 2:
The crimping process itself performs the function of stripping the insulating coating. The serrated tines automatically peel away the coating as they are crimped around the wire, making the connection process self-sufficient and eliminating the need for separate stripping equipment or operations, thereby reducing complexity while maintaining connection quality
Data Source
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AI summary
Splices for the electrical connection of flat magnetic wires are described, wherein the splices comprise a base, a first tine and a second tine, each protruding from one of the two opposite extremities of the base so as to form a U-shaped structure. The base of the splice is flat so as to define an XY plane, wherein the Y direction is parallel to the insertion direction of the flat magnetic wire into the splice. According to a first aspect, the first tine and the second tine are asymmetric, so as to allow an overlapping crimping of the first tine and the second tine around the flat magnetic wire. Alternatively, according to a second aspect, the splice, in an elongated state, has a length greater than 19 mm for example comprised between 19.1 mm and 30 mm, for example of 20.95 mm or 28.51 mm.