Bi-Metallic Terminal Fitting Spring Back Suppression
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Solution Overview
Problem
The use of copper or copper alloy terminal fittings with spring pieces results in an imperfect contact with aluminum or aluminum alloy core wires due to higher spring back properties, leading to increased contact resistance and loose crimping.
Innovation Solution
A terminal fitting with a copper or copper alloy main body and an aluminum terminal for crimping, where the aluminum terminal is caulked to suppress the spring back of the copper terminal fitting, ensuring high contact pressure through matching spring back properties and an interference fit structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum terminal is added to copper terminal fitting, then contact pressure is improved, but device complexity increases
Solution Approach 1:
The aluminum terminal is merged with the copper terminal fitting main body to form an integrated assembly. The aluminum terminal includes a bottom wall and caulking pieces that are structurally combined with the copper body, creating a unified terminal fitting that achieves high contact pressure without requiring separate complex components.
Solution Approach 2:
The copper terminal fitting main body serves multiple functions: providing the spring property needed for maintaining contact pressure, ensuring electrical conductivity, and serving as the structural base for the aluminum terminal. This multi-functionality reduces the need for additional components, simplifying the overall structure despite the bi-metallic design.
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 configuration securely mounts aluminum or aluminum alloy core wires by reducing contact resistance and enhancing contact pressure, ensuring a stable electrical connection.
Implementation Method 1
copper or copper alloy has a greater spring back property than aluminum or aluminum alloy. Therefore, if the terminal fitting 20 made of copper or copper alloy is caulked to crimp the core wires 11 made of aluminum or aluminum alloy, the core wires are placed in a loose crimped state
Implementation Method 2
an aluminum terminal made of aluminum or aluminum alloy for caulking the wire connection portion and the core wire, the aluminum terminal including a first bottom wall, and a first pair of caulking pieces that are stood from the first bottom wall
Data Source
AI summary
An aluminum (Al) terminal has a first bottom wall, and a pair of caulking pieces that are stood from the first bottom wall and caulked in a state where the first bottom wall covers a wire connection portion with the core wires arranged on the upper side from the underside. Thereby, the Al terminal made of Al or Al alloy can be crimped from outside the terminal fitting main body made of copper or copper alloy, and the spring back of the terminal fitting main body made of copper or copper alloy can be suppressed by the Al terminal.