Radially Compressed Electrical Conductor for Crimping
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Solution Overview
Problem
The irregular diameters of electrical conductors due to manufacturing tolerances and differences in conductor sizes lead to inefficiencies and waste during crimping, particularly when shielding braid strands protrude from the crimp seam, resulting in excessive production waste.
Innovation Solution
An intermediate product with a radially compressed core along the longitudinal axis of the electrical conductor, allowing for a standardized crimp sleeve fit, where the shielding braid is compressed to a uniform diameter using methods like ultrasound welding, preventing stray strands and facilitating crimping by creating a homogeneous core with minimal contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrical conductors are manufactured with standard tolerances, then manufacturing cost and ease of production are improved, but manufacturing precision deteriorates resulting in irregular diameters and shielding braid protrusions
Solution Approach 1:
The shielding braid is pre-compressed radially before the crimping operation to create a uniform diameter core. This preliminary action ensures that when the crimp sleeve is later applied, the shielding braid strands remain contained and do not protrude from the crimp seam, thereby achieving both ease of manufacture and improved manufacturing precision.
2Manufacturing precision
If radial compression is applied to the shielding braid, then manufacturing precision is improved with uniform diameter, but device complexity increases due to additional processing steps
Solution Approach 1:
The radial compression of the shielding braid is combined with the existing crimping process by integrating the compression step into the preparation phase before crimp sleeve application. This merging approach achieves uniform diameter (improving manufacturing precision) while utilizing existing equipment and process flows, thereby limiting the increase in device complexity.
3Ease of manufacture
If shielding braid strands protrude from crimp seam, then manufacturing simplicity is maintained, but loss of substance increases due to excessive waste
Solution Approach 1:
By pre-compressing the shielding braid radially to create a uniform diameter core before crimping, the invention prevents shielding braid strands from protruding during the crimping operation. This preliminary compression action eliminates the need for subsequent trimming or removal of protruding strands, thereby reducing material waste while maintaining manufacturing simplicity.
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 solution reduces errors and waste in crimped conductor manufacturing by ensuring a uniform diameter for the crimp sleeve, enabling efficient coupling of diverse conductors to identical components and reducing component variability, thus lowering costs.
Implementation Method 1
wherein the shielding braid is compressed to a uniform diameter using methods like ultrasound welding
Data Source
AI summary
An intermediate product for crimping includes an electrical conductor extending along a longitudinal axis. The electrical conductor has a shielding braid and an insulation at least partially enclosing the shielding braid. The electrical conductor has a radially compressed core in a region along the longitudinal axis.