Crimp Terminal Circular Recesses for Contact Conductivity
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Solution Overview
Problem
Existing crimp terminals with linear serrations on the conductor crimp portion fail to maintain high contact conductivity when the conductor extends in directions other than the longitudinal direction, due to gaps at the inner corner portions and increased contact resistance from thermal shock and mechanical vibrations.
Innovation Solution
The crimp terminal incorporates small circular recesses as serrations on the conductor crimp portion, formed through press machining using a metal mold with protruded portions created by discharge machining, which reduces gaps and enhances oxide film peeling, maintaining contact conductivity regardless of conductor direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If linear serrations are used on the conductor crimp portion, then the structure is simple and easy to manufacture, but gaps form at inner corner portions and contact resistance increases under thermal shock and mechanical vibrations
Solution Approach 1:
The patent replaces linear serrations with circular recesses on the inner surface of the conductor crimp portion. The circular shape eliminates sharp inner corner portions where gaps previously formed, providing a continuous curved surface that maintains better contact under thermal shock and mechanical vibrations. This curvature modification directly addresses the reliability issue while remaining compatible with standard press machining processes.
Solution Approach 2:
The patent modifies the geometric parameters of the serrations by changing from linear grooves to circular recesses with specific radius values (R1 for inner corner portions, R2 for hole edges). These parameter changes optimize the contact surface geometry to prevent gap formation and reduce contact resistance variations under environmental stress.
2Manufacturing precision
If discharge machining is used to form protruded portions in the metal mold, then circular protruded portions with precise roundness are achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent replaces traditional mechanical grinding methods with discharge machining to form the protruded portions in the metal mold. This substitution enables precise control of roundness parameters (R1 and R2) through electrical erosion rather than mechanical abrasion, achieving superior geometric precision while simplifying the overall manufacturing workflow.
Solution Approach 2:
The patent specifies precise dimensional parameters for the protruded portions formed by discharge machining, including radius R1 for the inner corner portions and radius R2 for the hole edges. These controlled parameters ensure consistent quality of the circular recesses in the final crimp terminal while maintaining manufacturing efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The crimp terminal achieves improved contact conduction performance by reducing gaps and increasing frictional mating, maintaining stable conductivity and durability through the use of discharge machining for forming circular protruded portions.
Implementation Method 1
formed, by a discharge machining, in a position corresponding to each of the recesses
Implementation Method 2
each of the recesses is formed through a press machining of the conductor crimp portion by using a metal mold with a protruded portion
Implementation Method 3
the surface of the conductor caused to flow by the pressing force causes a frictional mating with the hole edge of the recess or the surface of the conductor entering into the recess causes a frictional mating with the inner side surface of the recess, thereby an oxide film of the surface of the conductor is peeled off
Data Source
AI summary
A conductor crimp portion (11) before being crimped to a conductor of an electric wire includes, in an inner surface (11R) of the conductor crimp portion (11), circular recesses (20) as serrations of the conductor crimp portion (11) scattered to be spaced from each other. Each of the recesses (20) is formed through a press machining of the conductor crimp portion (11) by using a metal mold (70) with a protruded portion (72) formed, by a discharge machining, in a position corresponding to each of the recesses (20) or by using a metal mold with a protruded portion (85) formed, by press fitting a pin (83) into a press fit hole (82) formed in a block (81), in a position corresponding to each of the recesses (20).