Crimp Terminal With Angled Side Portions For Firm Wire Fixing
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Solution Overview
Problem
Existing crimp terminals fail to firmly fix core wires of lead wires, leading to potential disconnection and variability in contact resistance due to insufficient adhesion.
Innovation Solution
A crimp body with specific dimensions and geometrical features, including a crimp height of 1.20 ± 0.05 mm, crimp width of 1.66 ± 0.05 mm, and angled side portions, ensures sufficient compression and balanced crimping of core wires, preventing excessive crushing and ensuring strong adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the crimp terminal uses conventional dimensions and geometry, then the structure is simple, but the core wires cannot be fixed firmly
Solution Approach 1:
The patent applies parameter changes by optimizing specific dimensional parameters of the holding portion: crimp height CH is set to 1.20 ± 0.05 mm, crimp width CW is set to 1.66 ± 0.05 mm, and the angle α between side portions is controlled at 0° or more and 30° or less. These precise parameter specifications transform the conventional crimp terminal into one that achieves firm wire fixing through controlled compression without excessive complexity.
Solution Approach 2:
The patent implements local quality by creating a specifically optimized holding portion with distinct geometric features (curved first and second side portions facing each other, with distal end portions that can bite into wires) that differs from the rest of the crimp terminal structure. This localized optimization of the holding portion's geometry provides enhanced fixing capability without requiring the entire terminal to be complex.
2Strength
If the side portions are curved to increase compression, then the adhesion between crimp terminal and core wires is improved, but the risk of excessive crushing increases
Solution Approach 1:
The patent resolves this contradiction through parameter changes by controlling the angle α between the first and second side portions at 0° or more and 30° or less, and by specifying the crimp height CH as 1.20 ± 0.05 mm. These parameter controls ensure sufficient compression for strong adhesion while preventing excessive crushing that would damage the core wires.
Solution Approach 2:
The patent applies partial action by having only the distal end portions of the first and second side portions curve toward each other to bite into the core wires, while the base portions remain relatively straight. This localized curvature provides the necessary compression force for strong adhesion without applying excessive force across the entire crimping area, thus avoiding wire damage.
3Reliability
If the crimp height and crimp width are increased, then the compression of core wires is sufficient, but the contact resistance variation increases
Solution Approach 1:
The patent resolves this contradiction through precise parameter changes: crimp height CH is set to 1.20 ± 0.05 mm and crimp width CW is set to 1.66 ± 0.05 mm. The tight tolerances (±0.05 mm) ensure consistent compression across production batches, providing sufficient compression for reliability while maintaining contact resistance consistency through controlled precision.
Data Source
Figure 1
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AI summary
In a holding portion 71g of a contact fitting, in a state before crimping of core wires, the thickness T1 of a first distal end portion 72a and the thickness T2 of a second distal end portion 73a are both 70% or less of the thickness Sa of the bottom portion 74. The thicknesses T1 and T2 are both smaller than the diameter of core wires of a lead wire to be crimped. The first distal end portion 72a and the second distal end portion 73a are formed by compression processing. Using the holding portion 71g, a first side portion 72 and a second side portion 73 are curved such that they face the bottom portion 74, and the plurality of core wires are surrounded and crimped with the bottom portion 74, the first side portion 72, and the second side portion 73.