Crimp Barrel Offset Impressions for Damage-Free Cable Contact
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Solution Overview
Problem
Existing contact elements connected to electric cables via crimping often damage the conductor due to the displacement caused by the shaped-in part, leading to poor electrical and mechanical connections.
Innovation Solution
A crimp barrel with offset impressions and a protuberance is designed to press against the conductor's outer circumferential side, forming a frictional connection and maintaining the conductor's shape to prevent damage while ensuring a secure and reliable electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional crimp contact is pressed into the electric cable, then the contact element is mechanically connected to the conductor, but the conductor is displaced or damaged by the shaped-in part of the contact element
Solution Approach 1:
The crimp barrel is designed with differentiated local properties: the outer circumferential side features pressing elements (impresses/protuberances) for mechanical engagement with the conductor, while the inner circumferential side maintains a smooth, shape-preserving surface. This local quality differentiation enables the crimp barrel to simultaneously achieve strong mechanical connection through external pressing elements while preventing conductor damage through a gentle internal surface that conforms to the conductor's original shape.
2Reliability
If the contact element is crimped onto the conductor, then electrical contact is established, but the conductor shape is distorted leading to poor electrical connection
Solution Approach 1:
The crimp barrel's inner circumferential side is specifically designed with a smooth, shape-preserving surface that locally conforms to the conductor's geometry, preventing distortion and maintaining manufacturing precision. Meanwhile, the outer circumferential side incorporates pressing elements that locally engage the conductor's outer surface, establishing reliable electrical contact without compromising the conductor's overall shape integrity.
Solution Approach 2:
The crimp barrel acts as an intermediary component between the contact element and the conductor. Its specially designed inner circumferential side serves as a mediating surface that receives the conductor without distorting it, while its outer circumferential side with pressing elements mediates the mechanical and electrical connection. This intermediary structure protects the conductor from direct damaging contact while ensuring reliable electrical connection.
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 solution prevents conductor damage during crimping, maintains a secure mechanical connection, and ensures durable and reliable electrical contact, even under high vibration conditions.
Implementation Method 1
forming a frictional connection and maintaining the conductor's shape to prevent damage
Data Source
AI summary
An arrangement includes an electric cable having a first electric conductor and a contact device having a crimp barrel and a contact element mechanically and electrically connected to the crimp barrel. The crimp barrel extends along an axis and has a first inner circumferential side and a first outer circumferential side. A first impress and a second impress are stamped into a first sub-portion of the crimp barrel, the second impress is offset circumferentially from the first impress with respect to the axis. The first inner circumferential side is shaped by the first impress and the second impress in such a manner that the first inner circumferential side is pressed against a second outer circumferential side of the first electric conductor and electrically contacts the second outer circumferential side, with the first inner circumferential side fitting against the second outer circumferential side.