Combocrimp Die Set Knurling and Embossing
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Solution Overview
Problem
Conventional crimp die sets require two separate sets for surface preparation and embossing an identification number, leading to inefficiencies, increased costs, and potential for errors due to the need for multiple die sets and time-consuming process switching.
Innovation Solution
A single 'combocrimp' die set with cooperating die members featuring knurls and embossed identification numbers, capable of both preparing the crimp surface and embossing the identification number in a single operation, reducing inventory and streamlining the crimping process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two separate die sets are used for surface preparation and embossing, then each function can be performed with specialized tools, but the process time increases and inventory requirements increase
Solution Approach 1:
The patent combines surface preparation knurls and embossing characters into a single die member, eliminating the need to change dies between operations. The die member includes both knurling surfaces and character impressions that are applied simultaneously during one crimping operation, thus resolving the time loss from die switching while maintaining specialized functions.
Solution Approach 2:
The die member is designed to perform multiple functions: surface knurling preparation and character embossing, both in a single tool. This multi-functional die eliminates the need for separate specialized dies, reducing inventory requirements and process time while maintaining the precision of both functions.
2Manufacturing precision
If two separate die sets are used for surface preparation and embossing, then each function can be optimized independently, but inventory costs and complexity increase
Solution Approach 1:
The patent merges the functionality of multiple die sets into a single integrated die member that includes both knurling surfaces and character embossing features. This reduction in the number of separate components simplifies inventory management and reduces device complexity while maintaining the precision of both surface preparation and embossing functions.
3Reliability
If multiple die sets are required, then specialized functions can be maintained, but the risk of selecting the wrong die increases
Solution Approach 1:
By combining surface preparation and embossing functions into a single die member, the patent eliminates the risk of selecting the wrong die for either function. The integrated design ensures that both functions are performed together with the correct parameters, improving compliance accuracy while maintaining functional reliability.
4Productivity
If a single die set performs both functions, then process efficiency increases, but the die design becomes more complex
Solution Approach 1:
The die member is designed as a universal component that performs both surface knurling and character embossing through integrated features. The multi-functional design achieves high productivity by eliminating die changes, while the complexity is managed through a unified structure rather than multiple separate components.
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 combocrimp die set significantly reduces the time and cost associated with crimping operations by allowing a single die set to both condition the surface and emboss identification numbers, minimizing errors and inventory needs while ensuring compliance with UL standards.
Implementation Method 1
Knurling dies are a set of dies that include a field of raised features that will deform the surface(s) of substrate under pressure to leave the surface(s) textured
Implementation Method 2
The die members in turn displace and deform the metal substrate surface with an imprint of the topography of the die member faces
Implementation Method 3
the crimp tool is positioned such that its jaws accept the connection area of the substrate and then operated to squeeze the metal substrate under force (up to 12 tons) between the die members
Data Source
AI summary
A die set for crimping operations includes first and second die members having raised areas including a plurality of knurls and character areas. The die set combining knurls and character areas on the operative areas of the die members allows a single die set to be used to condition a surface for crimping operations as well as crimping connectors and marking them with relevant indicia without having to change die sets.