Crimp Terminal Bend Portion Compression Control
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Solution Overview
Problem
Conventional crimp terminal configurations for electrical wires are complex and prone to high compression in certain areas, leading to damage and reduced holding force due to the shape and compression patterns of the terminal fittings.
Innovation Solution
A simplified crimp terminal design featuring a receiving portion, pair of first barrel portions, a bend portion, and an overlap portion, where the bend portion extends from the end of the receiving portion to allow for a shorter path and controlled compression, reducing damage and maintaining holding force by adjusting the compression rates across different areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the extension piece extends from a side edge of the bottom plate and the second barrel portion and connection portion are laid over the bottom plate, then the electrical wire can be crimped with high compression to rupture oxide films and reduce electrical resistance, but the shape of the terminal fitting becomes complex
Solution Approach 1:
The patent inverts the conventional approach by extending the bend portion from the end portion of the receiving portion rather than from the side edge of the bottom plate. This reversal simplifies the overall shape while maintaining the necessary compression zones for electrical connection.
Solution Approach 2:
The patent modifies the geometric parameters of the terminal fitting by changing the extension direction and position of the bend portion. This parameter change simplifies the shape complexity while preserving the functional compression zones needed for reliable electrical connection.
2Device complexity
If the bend portion is folded over in a bypass manner from the end portion of the receiving portion, then the configuration might be simpler, but the path of the bend portion and overlap portion becomes longer
Solution Approach 1:
The bend portion is positioned and configured in advance to extend directly from the end portion of the receiving portion, optimizing the path length before the crimping operation occurs. This preliminary configuration ensures the shortest necessary path while maintaining structural simplicity.
3Reliability
If high compression is applied to the conductor portion to rupture oxide films and reduce electrical resistance, then electrical connection quality improves, but conductor damage increases and holding force decreases
Solution Approach 1:
The patent applies different compression rates to different regions of the terminal fitting. High compression is applied locally at the overlap portion to rupture oxide films and ensure good electrical connection, while low compression is applied at the end portion to maintain conductor holding force and prevent damage.
Solution Approach 2:
The patent uses partial compression action by applying high compression only where needed (at the overlap portion for electrical connection) rather than uniformly across the entire terminal fitting, thereby avoiding excessive compression that would damage the conductor and reduce holding force.
Data Source
AI summary
A crimp terminal may include: a receiving portion that is to receive conductor portions of electrical wires and has an end portion from which the electrical wires are to be lead out; a pair of first barrel portions that are connected to the receiving portion and compress the conductor portions along with the receiving portion; a bend portion that extends from an end portion of the receiving portion and is bent so as to be folded over; and an overlap portion that is connected to the bend portion and overlaps the receiving portion.