Crimp Contact Sidewall Geometry for Multi-Gauge Wire Grip
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Solution Overview
Problem
Existing crimp contacts are limited in their ability to grip a wide range of wire gauges, requiring multiple contacts and tools for different wire sizes, and fail to provide sufficient gripping force across varying conductor densities and distributions.
Innovation Solution
A crimp contact design featuring centerline-based sidewalls with leg and base sections of varying lateral distances, allowing for deformation to engage wire conductors across a broader gauge range and increasing friction through varying conductor distribution within the contact cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a crimp contact is designed for a specific wire gauge range, then it provides reliable gripping force for that range, but it cannot grip wires of different gauges without requiring multiple contact designs
Solution Approach 1:
The crimp contact incorporates sidewalls with non-uniform thickness distribution, where the thickness varies along the longitudinal axis to create different engagement zones. This local variation in geometric properties allows a single contact design to adapt to multiple wire gauge ranges, resolving the contradiction between versatility and design complexity
Solution Approach 2:
The crimp contact is designed to be deformed during the crimping process, transforming from a rigid pre-formed structure to a dynamically adapted shape that conforms to the specific wire bundle being connected. This dynamic deformation capability enables a single contact design to effectively engage different wire gauges
2Strength
If the crimp contact is deformed to grip wire conductors, then mechanical connection is achieved, but the gripping force may be insufficient for varying conductor densities
Solution Approach 1:
The sidewalls are designed with varying thickness at different locations, creating zones of different compliance and engagement characteristics. Thinner sections provide higher compliance for dense conductor bundles, while thicker sections provide structural support for larger gauge wires, enabling effective gripping across varying conductor densities
Solution Approach 2:
The crimp contact utilizes changes in geometric parameters (thickness, width, length) along its structure to adapt to different wire configurations. The non-uniform thickness distribution creates varying mechanical properties that adjust the gripping force to match different conductor densities and arrangements
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 crimp contact effectively grips a wider range of wire gauges, providing enhanced mechanical and electrical connectivity with increased resistance to wire removal due to higher frictional forces, eliminating the need for multiple contacts and tools.
Implementation Method 1
increased resistance to wire removal due to higher frictional forces
Data Source
AI summary
A cable assembly (100) includes an electrical wire (106) having a terminal end (108) that includes at least one exposed wire conductor (110). The cable assembly (100) also includes a crimp contact (105) having a centerline and first and second sidewalls (124, 126) extending from the centerline in opposite directions. The centerline extends parallel to a longitudinal axis (190) of the crimp contact (105). Each sidewall (124, 126) has a base section (132, 142) and a leg section (134, 144). The leg section (134, 144) extends a lateral distance from the centerline to a longitudinal edge (164, 174) of the leg section. The base section (132, 142) extends a lateral distance from the centerline to a longitudinal edge (162, 172) of the base section. The lateral distance of the leg section (134, 144) is greater than the lateral distance of the base section (132, 142) for each of the first and second sidewalls (124, 126). The leg sections (164, 174) of the first and second sidewalls (124, 126) are located opposite the base sections (172, 162) of the second and first sidewalls (126, 124), respectively. The first and second sidewalls (124, 126) surround and engage the at least one wire conductor (110).