Crimp Segment Staggered Seam Mechanical Stability
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Solution Overview
Problem
Crimp connections in electromechanical connectors face issues with mechanical and electrical robustness, particularly with thinner stock materials, leading to potential relative movement of wires and reduced crimping forces, which can result in increased electrical transition resistances and vulnerability to corrosion.
Innovation Solution
A crimp segment with a crimp barrel featuring a staggered seam and embossed/deepened regions on the side walls, forming a rigid interlock that prevents axial displacement and enhances mechanical stability, using materials like copper or copper alloys, and potentially coated with nickel for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thinner stock materials are used for the crimp barrel, then manufacturing difficulties and costs are reduced, but mechanical stability and resistance to bending are worsened
Solution Approach 1:
The crimp barrel is segmented into multiple sections along its longitudinal axis, with transverse slots creating distinct segments. This segmentation allows the thin-walled barrel to maintain flexibility while distributing mechanical stresses, preventing catastrophic failure and maintaining structural integrity despite reduced material thickness
Solution Approach 2:
The invention employs a composite structure combining the crimp barrel, crimp flanks, and interlocking elements as an integrated system. The specific material composition (copper or copper alloys, potentially nickel-coated) creates a composite material system that achieves enhanced strength-to-weight ratio, allowing thinner walls while maintaining mechanical stability
2Reliability
If conventional crimp connections are used, then electrical connections are established, but relative movement of wires and reduced crimping forces occur under mechanical stress
Solution Approach 1:
The crimp barrel is divided into multiple segments by transverse slots, allowing controlled deformation and stress distribution. This segmentation prevents the barrel from acting as a rigid unit that could crack, while maintaining sufficient structural integrity to prevent wire movement and maintain electrical connection reliability
Solution Approach 2:
The invention changes the geometric parameters of the crimp barrel, specifically the wall thickness and the introduction of transverse slots. These parameter changes allow the barrel to deform in a controlled manner under mechanical stress, maintaining crimping forces and preventing wire displacement while using thinner materials
Data Source
AI summary
A crimp segment comprises a crimp barrel having a base and a pair of opposing side walls extending from the base. Each of the side walls is adapted to bend around a plurality of wires disposed in the crimp barrel and a pair of ends of the side walls engage with one another along a staggered seam.