Crimp Connector with Level Clamping Surfaces for Wire Fixing
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Solution Overview
Problem
Existing crimp connectors often damage delicate wires due to deformation during connection, as they require significant deformation to establish a secure mechanical and electrical bond, which is not suitable for wires that cannot resist such deformation.
Innovation Solution
A crimp connector design featuring two clamping plates with level inner surfaces that displace to enclose a harder wire, creating a force-fitting joint with minimal deformation, supplemented by a form-fitting joint using a back gripping surface to securely hold the wire without kinking or breaking it, allowing for secure attachment with reduced sensitivity to wire thickness and surface tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a projection and recess structure is used to create a form-fitting joint, then the mechanical connection strength is improved, but the wire is deformed significantly which damages delicate wires
Solution Approach 1:
Instead of deforming the wire to fit into a recess (conventional approach), the invention inverts the approach by having the wire press into the clamping plate material. The wire's hardness enables it to displace the softer clamping plate material and create its own embedding path, thereby avoiding wire deformation while achieving strong mechanical connection.
Solution Approach 2:
The invention changes the hardness parameter relationship between the wire and clamping plates. By specifying that the wire material is harder than the clamping plate material, the wire can actively displace and embed into the clamping plate material without significant wire deformation, resolving the contradiction between connection strength and wire integrity.
2Device complexity
If conventional clamping plates are used, then the connection is simple, but it is highly sensitive to wire thickness tolerances and surface unevenness
Solution Approach 1:
The invention changes the material hardness parameter to make the wire harder than the clamping plates. This enables the wire to actively press into and embed within the clamping plate material, creating a connection that is less sensitive to dimensional tolerances and surface variations, thereby improving reliability while maintaining structural simplicity.
Solution Approach 2:
The invention employs rounded gripping surfaces and curved embedding paths instead of sharp edges or flat contact surfaces. This curvature allows the wire to smoothly embed into the clamping plate material, reducing stress concentration and making the connection more tolerant of manufacturing variations.
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 provides a robust, secure mechanical and electrical connection with reduced risk of wire damage, maintaining the wire's integrity by minimizing deformation and ensuring high tensile strength through a large-surface contact and gentle deflection, suitable for a wide range of wire thicknesses and surfaces.
Implementation Method 1
the size of the longitudinal wire section presses partially into one clamping surface and partially into the other one by displacing the clamping plate material
Implementation Method 2
the clamping plates make contact to one another with their clamping surfaces
Data Source
AI summary
The connection refers to a connecting arrangement with a crimp connector (2) and a wire (3) fixed in place to the crimp connector. The crimp connector encompasses two clamping plates (4, 5) executed as one piece that, in a mounted state, clamp the wire (3) between them and while doing, so fix the wire (3) firmly in place with a force acting in longitudinal axial load direction (B). At least in the mounted state, the inner surfaces of the clamping plates face one another and are at least partially executed as level clamping surfaces (4a, 5a). In the mounted state, the clamping surfaces (4a, 5a) of the clamping plates (4, 5) make contact with one another, whereby an area of the wire section (3′) is pressed partially inside the one clamping plate and partially inside the other clamping plate (4, 5). At least one clamping plate (4, 5) has at least one back gripping surface (8) colliding with its clamping surface (4a, 5a) facing against the load direction (B) and extending transversally to the load direction (B), whereby the clamping surface (4a, 5a) of the other clamping plate (4, 5) extends beyond the back gripping surface (8) against the load direction (B).