Cable Connector Segmented Crimping for Mixed Cross-Sections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical cable connectors with a single core crimp area face challenges in achieving both low contact resistance and high mechanical strength, particularly when connecting cables with different cross-sections, as excessive compression can lead to core shearing and impaired mechanical strength.
Innovation Solution
The cable connector features multiple crimp sections with different developments, allowing for tailored compression levels and increased contact area, enabling the connection of cables with varying cross-sections while maintaining mechanical resilience and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cable connector is pressed onto the cores with a moderate force, then the mechanical strength of the connection is preserved and cores are prevented from shearing off, but the electrical connection does not achieve its lowest possible contact resistance
Solution Approach 1:
The crimping area is divided into multiple crimping sections with different developments, allowing each section to perform a specific function: some sections provide mechanical fastening while others optimize electrical contact, thus resolving the contradiction between mechanical strength and electrical conductivity
Solution Approach 2:
Different crimping sections are designed with different local properties (different developments) to achieve different objectives: sections with smaller developments provide mechanical anchoring while sections with larger developments ensure low contact resistance, allowing both requirements to be met simultaneously
2Device complexity
If a cable connector with only one pair of core crimping elements is used to connect cables with different cross-sections, then device complexity is reduced, but the cores with large cross-section are compressed just enough while small cross-section cores are overcompressed and risk shearing
Solution Approach 1:
The single crimping area is segmented into multiple crimping sections with different developments, enabling the same connector structure to accommodate cables with different cross-sections without overcompression, thus maintaining connection reliability while keeping device complexity low
Solution Approach 2:
The developments of different crimping sections are designed with specific parameter variations to match different cable core sizes, allowing the connector to adapt to various cross-sections and prevent core shearing while maintaining connection reliability
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 design enhances mechanical strength and electrical conductivity, allowing for a higher ratio of cable core diameters and improved long-term stability, especially when connecting thin cables, by ensuring appropriate compression and reduced risk of core shearing.
Implementation Method 1
During compression, the approximately round cores or individual strands are plastically deformed into an irregular, polygonal, honeycomb-shaped cross-section and thus a compression of the cable core, which increases the contact surface of the cores to one another and to the cable lug.
Data Source
Figure 1A~1C
Figure 1D~1F
Figure 2A~2C
AI summary
The connector (10) has a wire crimping region including several wire crimping elements (14) for fastening the wires of electrical cables. The crimping element has fastening crimping portions (18A,18B) and crimping contacts (16) between fastening crimping portions in longitudinal direction. The length of crimping contact along a longitudinal axis (L) perpendicular to the direction of extension is greater than the length of fastening crimping portion. The crimping portions and crimping contacts are symmetrical to the longitudinal axis.