Crimp Terminal With Segmented Circular Serrations
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Solution Overview
Problem
Conventional crimp terminals with three linear serrations have a limited edge length and volume, which restricts the stabilization of contact resistance and tensile strength due to a small new surface area and biting volume, and shallow central serrations may not adequately improve tensile strength.
Innovation Solution
A crimp terminal with a conductor crimp unit featuring multiple circular serrations of varying sizes, where small serrations are on the electric wire lead-out side and larger serrations are on the opposite side, increasing the total edge length and internal volume for improved contact resistance and tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If three linear serrations are used in the conductor crimp unit, then the structure is simple and easy to manufacture, but the total edge length and new surface area are limited, which restricts contact resistance stabilization and tensile strength improvement
Solution Approach 1:
The single linear serration is segmented into multiple serrations (first, second, third, and fourth serrations) arranged in different directions. This segmentation increases the total edge length and new surface area generated during crimping, thereby improving contact resistance stabilization and tensile strength while maintaining manufacturing simplicity through the use of standard forming processes
Solution Approach 2:
The serrations are arranged in multiple directions (different orientations) rather than along a single linear path. This dimensional expansion from one-dimensional linear arrangement to multi-dimensional spatial distribution significantly increases the total edge length and surface area contact with the conductor, enhancing electrical and mechanical performance
2Strength
If the central serration depth is reduced to minimize shearing damage, then shearing damage is reduced, but the biting volume and tensile strength improvement are insufficient
Solution Approach 1:
The single central serration is divided into multiple serrations distributed across different locations and directions. This allows the crimping force to be distributed across multiple biting points, achieving adequate tensile strength through cumulative biting volume while each individual serration maintains sufficient depth to minimize shearing damage
Solution Approach 2:
Different serrations are positioned at different locations (central and lateral positions) with potentially different depths and orientations optimized for their specific functions. The central serrations provide primary biting while lateral serrations distribute stress, creating local quality variations that optimize both tensile strength and minimize shearing damage in different regions
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 increased edge length and volume of circular serrations enhance contact resistance stabilization and tensile strength by reducing shearing damage and promoting a larger new surface area, effectively addressing the limitations of linear serrations.
Implementation Method 1
the conductor 60 part of the electric wire W is crimped by swaging deformation of the one pair of conductor swage units 54
Implementation Method 2
edge parts of the respective serrations 58a, 58b and 58c apply strong pressure locally on the conductor 60. Then, a resistive material such as an oxide generated on a surface of the conductor 60 at a part which has received the strong pressure is removed and a new surface which is excellent in conductivity is formed
Implementation Method 3
the conductor 60 that receives the crimping force in the course of swaging of the one pair of conductor swage units 54 is deformed in accordance with groove shapes of the respective serrations 58a, 58b and 58c
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3(a)~3(b)
AI summary
Disclosed is a crimp terminal (1) provided with a conductor crimp unit (3A) that has a base (4) and a swage unit (5), which extends from the sides of the base (4) and swages in such a manner that a conductor (20) on the base (4) is crimped. Circular serrations (10a, 10b) are multiply provided to the inner surface of the conductor crimp unit (3A). The serrations (10a, 10b) have different sizes according to region.