Crimp Barrel Sealing Wing for Aluminum Wire Termination
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Solution Overview
Problem
Aluminum conductors in electrical terminals face issues with oxide layers reducing conductivity and electrochemical corrosion, especially when used with copper-based terminals, and existing solutions like nickel plating or larger crimp barrels increase costs and complexity.
Innovation Solution
An electrical terminal design with a crimp barrel featuring sealing wings that create a pocket for a sealant, which is crimped over the wire to prevent moisture ingress and establish a reliable connection, using serrations to penetrate oxide layers, and ensuring no conductor exposure beyond the crimp barrel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If aluminum conductors are used to reduce cost, then material cost is reduced, but electrical conductivity deteriorates due to oxide layer formation
Solution Approach 1:
The crimp barrel includes serrations that protrude into the opening to mechanically penetrate and break through the aluminum oxide layer on the conductor surface before electrical connection is established. This preliminary mechanical action removes the insulating oxide barrier, enabling reliable electrical contact with aluminum conductors without requiring additional plating or complex surface treatment processes.
2Reliability
If copper-based electrical terminals are used, then electrical conductivity is improved, but electrochemical corrosion increases due to large electrochemical potential difference with aluminum
Solution Approach 1:
The crimp barrel acts as an intermediary component between the copper-based electrical terminal and the aluminum conductor. By positioning the serrated crimp barrel in direct contact with the aluminum conductor while the terminal contacts the crimp barrel, the design creates a galvanic isolation barrier that prevents direct electrochemical interaction between dissimilar metals, thereby eliminating corrosion risk while maintaining electrical conductivity through the crimp barrel interface.
3Object-affected harmful factors
If nickel plating is applied to crimp barrel to prevent corrosion, then corrosion resistance is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The design uses an unplated crimp barrel made from corrosion-resistant material or material suitable for the application environment, eliminating the need for expensive nickel plating processes. The crimp barrel is designed to be crimped directly over the conductor with the terminal, creating a simple three-component assembly that reduces manufacturing steps, tooling requirements, and overall production cost while maintaining adequate corrosion resistance for the application.
4Object-affected harmful factors
If aluminum plating is applied to crimp barrel to match conductor material, then galvanic corrosion is reduced, but plating process complexity and cost increase
Solution Approach 1:
The design extracts and eliminates the plating process entirely from the manufacturing sequence. By using a bare crimp barrel without any aluminum or other plating, the design simplifies the manufacturing process to basic forming and crimping operations, removing the need for complex plating equipment, process control, and quality inspection associated with thin-film deposition techniques.
5Object-affected harmful factors
If silicone gasket is used to seal crimp barrel ends, then moisture ingress is prevented, but space for larger aluminum conductor is reduced
Solution Approach 1:
The design merges the sealing function into the crimp barrel structure itself by forming the crimp barrel to extend beyond the conductor end, creating an inherent mechanical seal that prevents moisture ingress. This integrated approach eliminates the need for separate silicone gaskets or other sealing components, maximizing the internal volume available for the aluminum conductor while providing adequate moisture protection through the extended crimp barrel geometry.
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 design effectively prevents electrochemical corrosion and maintains conductivity by sealing the crimp interface and penetrating oxide layers, reducing the risk of corrosion and maintaining electrical integrity without increasing assembly costs.
Implementation Method 1
a sealing wing extends from the end of at least one of the side walls... a pocket is defined between the sealing wing and the corresponding side wall before the side walls are crimped over the end of the wire, the pocket comprising a sealant held therein
Implementation Method 2
as aluminum has a reduced amount of electrical conductivity relative to copper, aluminum conductors need to have a larger cross-sectional area... an oxide layer that may build on the exterior surface of the conductor. Such an oxide layer has relatively poor electrical conductivity. Accordingly, the oxide layer must be penetrated to the base material
Implementation Method 3
The crimp barrel is crimped around the end of the wire to establish an electrical connection between the one or more conductors of the wire and the terminal as well as to mechanically hold the electrical terminal on the wire end
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
An electrical terminal (10) having an electrical contact (18) and a crimp barrel (20) configured to be crimped around an end of a wire. The crimp barrel (20) includes a base (22) and opposing side walls (24) that define an opening (25) of the crimp barrel (20). The side walls (24) extend outwardly from the base (22) to ends (50) and include base segments (52) and end segments (54). A sealing wing (56) extends from the end of at least one of the side walls (24). The side walls (24) are configured to be folded over the wire when crimped such that a gap is defined between the end segment (54) and the base segment (52) of at least one of the side walls (24). The sealing wing (56) is configured to extend within the gap between the end segment (54) and the base segment (52) when the side walls (24) are crimped over the end of the wire.