Crimp Contact Insulation Retention via Segmented Fixing Device
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Solution Overview
Problem
Existing crimp contact devices fail to securely maintain the insulation of electrical cables during extreme loads, such as bending, leading to potential corrosion and contact issues due to insulation sliding out of the crimp region.
Innovation Solution
The crimp contact device incorporates a fixing device with multiple 3D structural sections, including grooves, ribs, cams, claws, and hooks, within the insulation crimp region to provide both frictional and positive-locking engagement, preventing the insulation from sliding and ensuring a secure mechanical clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single fixing device with serrations is used in the insulation crimp region, then the device complexity is reduced, but the insulation sliding resistance decreases under extreme loads
Solution Approach 1:
The fixing device is divided into multiple fixing sections (first fixing section with grooves, second fixing section with protrusions) that are arranged sequentially along the cable axis. This segmentation allows each section to provide different types of mechanical engagement (frictional and positive-locking), thereby improving insulation retention under extreme loads while maintaining a relatively simple overall structure.
Solution Approach 2:
Different regions of the fixing device are designed with different structural characteristics - the first fixing section has grooves for frictional engagement, while the second fixing section has protrusions for positive-locking engagement. This local differentiation of structural quality enables the fixing device to provide multiple mechanisms for preventing insulation slippage simultaneously.
2Manufacturing precision
If the insulation crimp region is made smooth and uniform, then the manufacturing precision is improved, but the mechanical clamping strength decreases under extreme conditions
Solution Approach 1:
The insulation crimp region transitions from a uniformly smooth structure to one with localized structural variations - grooves in the first fixing section and protrusions in the second fixing section. These localized features are precisely manufactured and provide enhanced mechanical engagement points without compromising the overall manufacturing precision of the crimp region.
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 insulation slippage and maintains a secure connection under extreme conditions, enhancing the reliability and durability of electrical connections in thermally loaded, dirty, and chemically aggressive environments.
Implementation Method 1
The fixing device is configured such that it creates friction between the insulation crimp region and the cable insulation
Implementation Method 2
The fixing device includes at least two fixing sections (332, 334), or (334, 334), that are delimited from each other
Data Source
AI summary
The invention relates to an electrical contact device and, in particular, a crimp contact device for a cable. The crimp contact device includes a cable conductor connection region and a cable insulation crimp region. The cable insulation crimp region includes a fixing device disposed along an inner surface thereof.