Crimp Barrel Curvature Geometry for Conductor Alignment
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Solution Overview
Problem
Crimp barrels for electrical conductors often result in incorrect production due to individual strands or shielding wires getting caught or protruding during the crimping process, which is exacerbated by the lack of availability of specific crimping tools.
Innovation Solution
A crimp barrel with a crimp base that is curved end-to-end and has a support region with a first curvature, accompanied by regions with a second curvature on both sides, where the curvature diameter of the second curvature is smaller, ensuring the electrical conductor is pressed against the support region before crimping, preventing strands from getting caught.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional crimp barrel is used without optimized geometry, then the crimping process is simpler, but individual strands or shielding wires get caught or protrude radially from the crimp barrel
Solution Approach 1:
The crimp barrel features a support region with a first curvature diameter that is larger than the curvature diameter in other regions. This local geometric variation creates a specific zone where electrical conductors are properly supported during crimping, preventing strands from getting caught while maintaining overall structural simplicity
Solution Approach 2:
The optimized crimp barrel geometry pre-position the electrical conductor in the correct location on the support region before crimping occurs. The curvature design automatically guides and secures the conductor in place, eliminating the need for additional crimping tool features to prevent strand protrusion
2Reliability
If specialized crimping tools with spring assemblies are used to press the electrical conductor onto the support region, then strands are prevented from getting caught, but the crimping tool becomes more complex and less available
Solution Approach 1:
The crimp barrel's support region with its specific curvature geometry automatically performs the function of pressing and positioning the electrical conductor during crimping. The geometric design itself provides the necessary guidance and support, eliminating the need for external spring assemblies or specialized tool features
Solution Approach 2:
The optimized support region acts as an intermediary element between the crimp barrel and the electrical conductor. Its specific curvature geometry mediates the interaction by automatically positioning and securing the conductor, replacing the need for complex intermediary mechanisms in the crimping tool
3Stability of the object's composition
If the crimp base is made more rigid to maintain structural stability, then the crimp barrel is more stable, but the crimp base cannot be properly deformed during crimping to adapt curvature diameters
Solution Approach 1:
The crimp base features a support region with different rigidity characteristics compared to other regions. The support region has a larger first curvature diameter that allows controlled deformation, while other parts of the crimp base maintain sufficient rigidity for overall structural stability during the crimping process
Solution Approach 2:
The crimp base is designed to dynamically adapt its shape during crimping. The support region deforms to match the curvature of the electrical conductor, allowing the curvature diameter to adapt from the larger first curvature to match the conductor's geometry, while the overall structure maintains stability
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a crimp barrel (1) prepared for crimping. The crimp barrel (1) according to the invention comprises a crimp base (6) that is disposed between two crimp wings (4) and that is provided with a support region (8) for the electrical conductor (3), wherein the support region (8) has a first curvature (10). Furthermore, disposed on both sides of the support region (8) in a circumferential direction (U), in which at least support region (8) is curved, is a respective region (12) having a second curvature (14), wherein a curvature diameter of the second curvature (14) is smaller than a curvature diameter of the first curvature (10). It is further provided that a rigidity, in particular a flexural rigidity, in the support region (8) or even in the entire crimp base (6), is less than a rigidity, in particular a flexural rigidity, in the respective crimp wings (4).