Cable Holding Member Geometry for Reliable Crimp Contact
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Solution Overview
Problem
Existing cable connectors face issues with insufficient breaking of the cover of the cable due to expansion of the crimping portion, leading to high contact resistance, increased heat generation, and potential conduction failure, especially in cables with high adhesion between the core wire and cover.
Innovation Solution
A cable holding member with a guide portion that restricts the horizontal expansion of the crimping portion, featuring a recessed shape with varying inner wall widths to ensure proper fitting and crimping, enhancing the contact reliability between the core wire and crimping portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the crimping portion expands horizontally during crimping, then the crimping force is distributed, but the contact pressure between the core wire and crimping portion becomes insufficient
Solution Approach 1:
The guide portion is designed with non-uniform inner wall widths, where the first inner wall has a larger width and the second inner wall has a smaller width. This creates localized constraint zones that control the expansion of the crimping portion at specific locations, ensuring sufficient contact pressure at the crimping interface while allowing controlled deformation elsewhere.
Solution Approach 2:
The guide portion introduces a vertical dimension constraint by providing upper and lower guide surfaces that limit the horizontal expansion of the crimping portion in the width direction. This dimensional control transforms the crimping process from uncontrolled radial expansion to controlled deformation within defined geometric boundaries, improving contact reliability.
2Reliability
If the crimping portion is constrained to prevent expansion, then contact reliability improves, but the crimping process becomes more difficult
Solution Approach 1:
The guide portion provides constraints only at specific locations (first and second inner walls) rather than completely restricting the crimping portion. This localized guidance allows the crimping portion to deform adequately for reliable contact while preventing excessive expansion that would compromise contact pressure, balancing manufacturability with reliability.
Solution Approach 2:
The guide portion acts as an intermediary structure between the crimping portion and the external environment. It mediates the crimping process by providing controlled guidance surfaces that facilitate the deformation process while maintaining necessary constraints, making the crimping operation easier to perform reliably.
Data Source
AI summary
Provided is a cable holding device including: a housing includes a terminal having a crimping portion, a cable holding member includes an insertion hole and a guide portion, the crimping portion is insertable into the cable holding member through the insertion hole, the guide portion is provided in the insertion hole, has such a recessed shape that the crimping portion inserted into the insertion hole is fittable therein, and an inner wall of the guide portion includes a first inner wall and a second inner wall provided on a far side with respect to the first inner wall in the insertion hole, and a horizontal width of the second inner wall is set smaller than a horizontal width of the first inner wall such that the second inner wall restricts expansion of a horizontal width of the crimping portion when the crimping portion crimps the cable.