Crimp Contact Design for Cost-Effective Manufacturing
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Solution Overview
Problem
Conventional crimp contact manufacturing methods are costly and wasteful, requiring machining of conductive materials to achieve specific dimensions and varying lengths for different electrical connector applications.
Innovation Solution
A crimp contact design featuring an elongated contact body with a contact wall and sleeve wall, formed from a continuous sheet of material that can be deformed by a crimping tool to grip conductors, allowing for cost-effective production and adjustable lengths without significant material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining methods are used to manufacture crimp contacts, then precise dimensions and varying lengths can be achieved, but manufacturing costs increase and material waste occurs
Solution Approach 1:
The patent changes the manufacturing approach from subtractive machining to formative stamping and crimping processes. The crimp contact is formed by stamping a blank to specific dimensions and then using a crimping tool to deform the contact body to gripping dimensions, eliminating the need for costly machining operations while maintaining precision
Solution Approach 2:
The patent employs a disposable stamping blank that is formed into the crimp contact in a single stamping operation. This eliminates the need for expensive, reusable machining tools and fixtures, significantly reducing manufacturing costs while achieving the required dimensional precision
2Adaptability or versatility
If machining methods are adjusted to form crimp contacts of different lengths, then varying lengths for different applications can be achieved, but manufacturing costs increase and material waste increases
Solution Approach 1:
The patent segments the manufacturing process into stamping a standard blank and then selectively crimping different portions of the contact body. This allows the same blank to be used for multiple applications with different required lengths, reducing material waste while maintaining adaptability
Solution Approach 2:
The patent performs preliminary stamping of a standardized blank that contains all necessary features. Subsequent crimping operations then selectively deform portions of the blank to create the final shape and length, eliminating the need to machine different lengths from different blanks and reducing material waste
3Adaptability or versatility
If machining methods are adjusted to form crimp contacts of different lengths, then varying lengths for different applications can be achieved, but manufacturing complexity increases
Solution Approach 1:
The patent creates a universal stamping blank that can be used to manufacture crimp contacts of different lengths and configurations. The same blank design serves multiple applications, and the crimping tool is configured to perform different crimping patterns, simplifying the overall manufacturing process while maintaining versatility
Solution Approach 2:
The patent employs a dynamic crimping process where the crimping tool can be adjusted to deform the contact body in different patterns and to different extents. This allows a single stamping blank to be transformed into multiple final products with varying lengths and shapes, reducing manufacturing process complexity while maintaining adaptability
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 design reduces manufacturing costs and material waste by using a deformable sheet of material to create crimp contacts with precise dimensions and varying lengths, enabling efficient electrical connections while maintaining cost-effectiveness.
Implementation Method 1
The sleeve wall is sized to engage a crimping tool and the contact wall is configured to grip a conductor within the conductor-receiving passage when the sleeve and contact walls are deformed by the crimping tool
Implementation Method 2
the crimp contact may be compressed or deformed at the loading end thereby causing the crimp contact to grip the conductors within the conductor passage
Data Source
AI summary
A crimp contact that includes an elongated contact body having loading and mating ends and a central axis extending therebetween. The contact body includes a contact wall that extends around the central axis and that defines a conductor-receiving passage of the contact body proximate to the loading end. The contact wall has an outer surface. The crimp contact also includes a sleeve wall that extends around the central axis and the outer surface of the contact wall proximate to the loading end of the contact body. The sleeve wall is sized to engage a crimping tool and the contact wall is configured to grip a conductor within the conductor-receiving passage when the sleeve and contact walls are deformed by the crimping tool.