Crimp Insert Spikes for Electrical Continuity and Corrosion Resistance
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Solution Overview
Problem
Existing crimp inserts face rapid degradation due to corrosive attacks at scratches generated during assembly, which compromise electrical continuity between the insert and components.
Innovation Solution
The crimp insert features spikes on its second face, with edges sloping between 45 degrees and 60 degrees, to ensure electrical continuity without relying on claw washers, thereby minimizing scratches and corrosion risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a claw washer is used to ensure electrical continuity between the insert and the member, then electrical continuity is achieved, but scratches are generated on large surfaces which favor corrosive attacks and lead to rapid degradation
Solution Approach 1:
The invention replaces the claw washer's large surface scratching mechanism with localized spikes at specific points on the insert head. Each spike creates a localized penetration point rather than widespread surface damage. This localizes the contact area to minimal points while still achieving electrical continuity through direct metal-to-metal contact at these concentrated points, thereby eliminating the large surface scratches that previously facilitated corrosion.
Solution Approach 2:
The invention changes the geometric parameters of the contact interface by introducing spikes with specific dimensional characteristics (height, base diameter, tip angle) rather than relying on the claw washer's curved scratching surfaces. The spikes are designed with controlled dimensions to penetrate the member surface and create intimate electrical contact without generating extensive scratches, thus modifying the contact parameters to reduce corrosive attack susceptibility.
2Object-affected harmful factors
If spikes are provided on the second face of the head to ensure electrical continuity, then electrical continuity is achieved with minimal scratches, but the spikes must be precisely formed with specific slope angles
Solution Approach 1:
The spikes are pre-formed on the insert head during the manufacturing process rather than being created during assembly. This preliminary formation allows for precise control of spike geometry (height, base diameter, slope angle between 45-60 degrees) through controlled deformation of the head material. The spikes are created in advance with exact dimensional specifications to ensure proper penetration and electrical contact while minimizing surface damage, eliminating the need for complex assembly operations.
3Reliability
If the slope of the spike edge is between 45 degrees and 60 degrees, then the spikes effectively penetrate the member to ensure electrical continuity, but the manufacturing process becomes more complex
Solution Approach 1:
The invention specifies a particular range for the spike edge slope (45-60 degrees) as an optimal parameter range that balances penetration effectiveness with manufacturability. Within this range, the spikes achieve sufficient sharpness to penetrate the member and create reliable electrical contact, while avoiding excessively steep angles that would be difficult to manufacture. The parameter optimization ensures that standard forming processes can produce the spikes with adequate precision without requiring specialized equipment or complex multi-step operations.
Data Source
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AI summary
The insert has an electrically conducting body (1) comprising a head (3) placed at a longitudinal end of a barrel (2) of the body, where the body is covered with a protective coating. The barrel rises at the level of a first face (4a) of the head. The body comprises points (6) distributed at the level of periphery of a second face (4b) of the head. Each point has a top (8) connected to the second face of the head by an associated edge (6'), where slope of the edge with respect to a horizontal plane defined by the second face of the head lies between 45 degrees and 60 degrees. An independent claim is also included for an electrically conducting component device.