Crimp Die Curvature for Composite Core Conductor Integrity
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Solution Overview
Problem
Conventional crimp dies fail to effectively crimp composite core conductors without damaging their outer surface, due to inadequate control over the crimping process, resulting in gaps and uneven compression that can lead to fractures.
Innovation Solution
A crimp die with concave surfaces having different radii of curvature is used to securely crimp the composite core conductor, providing improved control and preventing damage by applying crimping forces at a 45-degree angle and ensuring a solid connection without gaps, thus maintaining the integrity of the composite core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional planar crimp surfaces are used, then the crimping process is simple, but gaps form between the dies and tubular portion resulting in poor crimp control and potential damage to the composite core
Solution Approach 1:
The patent applies curved crimp surfaces with specific radii of curvature (R1 and R2) instead of planar surfaces. The first crimp surface has a radius R1 and the second crimp surface has a radius R2, where R1 ≠ R2. This curvature design eliminates gaps between the dies and tubular portion during crimping, providing precise control over the crimping process while preventing damage to the composite core conductor.
2Force
If planar crimp surfaces are used, then the device structure is simple, but the area of compression between dies and tubular portion is reduced leading to insufficient crimping force distribution
Solution Approach 1:
The curved crimp surfaces with different radii (R1 and R2) create a larger contact area between the dies and the tubular portion during crimping. This increased compression area allows for better distribution of the crimping force, ensuring adequate compression of the composite core conductor without concentrating stress in localized areas that could cause damage.
3Manufacturing precision
If planar crimp surfaces applying forces at 31 degrees and 90 degrees are used, then the crimping process is conventional, but the crimp control is insufficient and gaps remain between dies and tubular portion
Solution Approach 1:
The patent employs curved surfaces with specifically engineered radii (R1 and R2) that guide the crimping forces more effectively. This geometric configuration ensures uniform crimping along the composite core conductor by eliminating gaps and providing consistent contact pressure, while the design remains manufacturable using standard die fabrication processes.
Solution Approach 2:
The patent changes the geometric parameters of the crimp surfaces from planar to curved, specifying particular radii of curvature (R1 and R2) as critical design parameters. This parameter change fundamentally improves crimp uniformity and control, transforming the crimping process from a gap-prone operation to a precisely controlled deformation process.
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 enables crimping of composite core conductors with enhanced control, preventing damage and ensuring a reliable, secure connection that maintains the conductor's performance without causing fractures or performance detriments.
Implementation Method 1
A crimped portion on the tubular portion radially engages the connecting portion and secures the conductor to the tubular portion. The crimped portion is formed by concave surfaces on internal surfaces of crimping dies.
Data Source
AI summary
An electrical connector for a composite core conductor and a method of controlling crimping thereof includes a coupling portion and a tubular portion extending from the coupling portion. A conductor has a non-metallic core surrounded by electrically conductive strands and has a connecting portion of the core extending axially beyond the strands. The connecting portion is received in the tubular portion. A crimped portion on the tubular portion radially engages the connecting portion and secures the conductor to the tubular portion. The crimped portion is formed by concave surfaces on internal surfaces of crimping dies. The concave surfaces have different radii of curvature than remaining portions of the internal surfaces.