Crimp Terminal With F-Type and C-Type Portions
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Solution Overview
Problem
C-type crimp portions face issues with uneven crimping of complex stranded wires, leading to reduced strength and increased resistance, as well as the reinforcement wire not being sufficiently fixed, causing the electric wire to potentially slip out of the crimp terminal under tensile forces.
Innovation Solution
An electric wire and crimp terminal arrangement featuring an F-type crimp portion with identical barrel tabs and a C-type crimp portion with a C-form barrel tab, where the F-type crimp portion compresses and grips the conductor element wires between the barrel tabs and the reinforcement wire, ensuring even crimping and sufficient fixation of the reinforcement wire, preventing the conductor element wires from protruding and reducing resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an F-type crimp portion with barrel tabs is used to crimp a complex stranded wire, then the crimp terminal can grip the wire, but the barrel tabs take bites into the wire making it difficult to place the reinforcement wire at the center, causing uneven forces and reduced strength of aluminum element wires
Solution Approach 1:
The crimp terminal is divided into two distinct crimping portions: an F-type crimp portion for gripping the tip end and a C-type crimp portion for enveloping the body portion. This segmentation allows each portion to perform its specific function optimally without interfering with wire placement, resolving the contradiction between gripping effectiveness and ease of operation.
Solution Approach 2:
Different portions of the crimp terminal have different structural characteristics tailored to their specific functions. The F-type portion has barrel tabs for gripping the tip end, while the C-type portion has a C-shaped structure for enveloping the body. This local differentiation enables even force distribution on aluminum element wires while facilitating proper wire placement.
2Strength
If a C-type crimp portion is used to crimp a complex stranded wire, then even crimping can be applied to aluminum element wires, but the reinforcement wire is not sufficiently fixed, causing the electric wire to potentially slip out under tensile forces
Solution Approach 1:
The crimp terminal is divided into two distinct crimping portions: an F-type crimp portion for gripping the tip end and a C-type crimp portion for enveloping the body portion. This segmentation allows each portion to perform its specific function optimally without interfering with wire placement, resolving the contradiction between gripping effectiveness and ease of operation.
Solution Approach 2:
The crimp terminal combines both F-type and C-type crimp portions into a single integrated structure. The F-type portion provides strong gripping at the tip end to prevent slippage, while the C-type portion provides even enveloping of the body portion. This merging of different crimping mechanisms into one terminal resolves the contradiction between even crimping and reliable fixation.
3Force
If barrel tabs are used in the F-type crimp portion, then the crimp terminal can grip the complex stranded wire, but concentrated forces act on some aluminum element wires, giving reduced sectional areas and decreased strengths
Solution Approach 1:
The crimp terminal is divided into two distinct crimping portions: an F-type crimp portion for gripping the tip end and a C-type crimp portion for enveloping the body portion. This segmentation allows each portion to perform its specific function optimally without interfering with wire placement, resolving the contradiction between gripping effectiveness and ease of operation.
Solution Approach 2:
Different portions of the crimp terminal have different structural characteristics tailored to their specific functions. The F-type portion has barrel tabs for gripping the tip end, while the C-type portion has a C-shaped structure for enveloping the body. This local differentiation enables even force distribution on aluminum element wires while facilitating proper wire placement.
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 solution ensures that the conductor element wires are evenly crimped, maintaining their strength, and the reinforcement wire is securely fixed, preventing the electric wire from slipping out of the crimp terminal, even under tensile forces, while maintaining a low production cost and flexibility.
Implementation Method 1
the F-type crimp portion being configured to have distal ends of the first and the second barrel tab put together to push into a tip end of the complex stranded wire to be crimped
Implementation Method 2
the C-type crimp portion being configured to have the third barrel tab wrapped in a C-form on an outer periphery of the complex stranded wire to be crimped
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
[Objective] To provide a crimp terminal and an electric wire with crimp terminal, allowing for a retained resistance not to be increased at a crimp portion, as well as an electric wire to be kept from slipping out of a crimp terminal. [Solution] A crimp terminal 11 includes an F-type crimp portion 13 and a C-type crimp portion 14, the F-type crimp portion 13 having a first and a second barrel tab 17 and 18 for crimping a tip end of a complex stranded wire, the first and the second barrel tab 17 and 18 having an identical length, the F-type crimp portion 13 being adapted to have distal ends of the first and the second barrel tab 17 and 18 put together and pushed into the tip end of the complex stranded wire to be crimped, the C-type crimp portion 14 having a third barrel tab 20 for crimping the complex stranded wire, the C-type crimp portion 14 having the third barrel tab 20 wound in a C-form on an outer periphery of the complex stranded wire to be crimped.