Crimp Die with Parallel Side Faces for Insulation Protection

Solution Overview

Problem

Existing crimp dies for electrical contact terminals often damage cable insulation or seal members during crimping, leading to micro-cracks and reduced mechanical connections, especially when using silicone-based seal members.

Innovation Solution

A crimp die design featuring a crimping ridge with parallel side face portions that extend in the crimping direction, preventing the inward rolling of insulation or sealing crimping wings and thus avoiding damage to the cable insulation or seal members, while maintaining a B-shaped cross-section for wire crimping wings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If insulation or sealing crimping wings are bent into a B-shaped form with inward rolling edges, then electrical connectivity is improved, but cable insulation or seal member is damaged causing micro-cracks

Engineering Contradiction:

Improveelectrical connectivityVSAvoiddamage to cable insulation or seal member

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The crimping operation is segmented into two distinct zones: a first crimping zone with a first crimping surface for forming B-shaped wire crimping wings with inward rolling edges for electrical connectivity, and a second crimping zone with a second crimping surface for forming round-shaped insulation crimping wings without edge rolling to avoid damage to cable insulation or seal members

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the crimp die are given different local qualities: the first crimping surface has a B-shaped cross-section with inclined sides to promote edge rolling for electrical contact, while the second crimping surface has a round cross-section with parallel sides to prevent edge rolling and avoid damage to insulation or seal members

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If insulation or sealing crimping wings are bent into a round shape, then damage to cable insulation or seal member is avoided, but electrical connectivity is reduced

Engineering Contradiction:

Improvedamage to cable insulation or seal memberVSAvoidelectrical connectivity

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The crimping operation is segmented into two distinct zones: a first crimping zone with a first crimping surface for forming B-shaped wire crimping wings with inward rolling edges for electrical connectivity, and a second crimping zone with a second crimping surface for forming round-shaped insulation crimping wings without edge rolling to avoid damage to cable insulation or seal members

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the crimp die are given different local qualities: the first crimping surface has a B-shaped cross-section with inclined sides to promote edge rolling for electrical contact, while the second crimping surface has a round cross-section with parallel sides to prevent edge rolling and avoid damage to insulation or seal members

Inventive Principle:

Principle #3Local quality

3Device complexity

If a single crimping surface is used for both wire and insulation crimping, then device complexity is reduced, but manufacturing precision is compromised

Engineering Contradiction:

Improvecrimp die structureVSAvoidcrimping shape control

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The crimp die is segmented into two distinct crimping surfaces: a first crimping surface with a B-shaped cross-section for wire crimping and a second crimping surface with a round cross-section for insulation crimping, allowing each surface to be optimized for its specific function without compromising the other

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The crimp die is designed as a multi-functional tool with two different crimping surfaces that can perform both wire crimping and insulation crimping operations in a single device, maintaining manufacturing precision for both operations simultaneously

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP2793326B1Insulation or sealing crimp die

Publication Date: 2017.09.13 DELPHI INT OPERATIONS LUXEMBOURG SARL

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AI summary

The present invention relates to a crimp die (101) comprising a main body (103), a first crimping leg (105), a second crimping leg (107) and a crimping ridge (111; 111'; 111") comprising two opposing side face portions (114; 114'; 114") which both extend in a direction essentially parallel to the longitudinal ridge axis, whereby the side face portions (114; 114'; 114") are essentially mutually parallel and extend from the main body (103) essentially in the crimping direction (601).