Closed Barrel Crimp Terminal Insertion Using an Insulation Guide
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Solution Overview
Problem
The insertion of multi-strand electrical conductors into closed barrel crimp terminals is challenging due to the risk of damaging the terminal or compromising the connection, as the strands may bend or fold, making it difficult to insert them properly.
Innovation Solution
A method involving cutting the insulating sheath of the electrical cable to separate it into three portions, removing the second portion to expose the conductor strands, and using the third portion as a retaining ring to guide the strands into the barrel portion of the crimp terminal, ensuring they are securely inserted and crimped.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multi-strand conductor strands are inserted directly into the closed barrel terminal, then the connection can be made, but the strands may bend or fold causing insertion difficulty and connection compromise
Solution Approach 1:
The patent applies preliminary action by pre-forming the insulation sheath into a guiding structure (U-shape or inverted U-shape) before the insertion process. This guiding structure is created during cable preparation, and it pre-establishes the path that the conductor strands will follow during insertion, preventing bending and folding before the strands even enter the terminal.
Solution Approach 2:
The patent uses the insulation sheath as an intermediary element between the conductor strands and the terminal barrel. By shaping the insulation sheath into a guiding structure, it acts as a mediator that guides the strands smoothly into the terminal without direct contact between the strands and the barrel inlet, eliminating the bending issue.
2Ease of operation
If the diameter ratio of closed barrel to cable is increased to ensure proper insertion, then insertion is facilitated, but extreme deformation of the barrel occurs during crimping causing terminal damage
Solution Approach 1:
The patent changes the geometric parameters of the insulation sheath by forming it into a U-shape or inverted U-shape with specific dimensions. The guiding structure has a depth and width designed to match the terminal barrel dimensions, creating an optimal fit that allows proper insertion without requiring an oversized barrel. This parameter optimization enables using a barrel with diameter closer to the cable diameter, reducing deformation during crimping.
Data Source
Figure 1~4B
Figure 5A~5E
Figure 6A~6C
AI summary
A method of preparing a connection for an electrical cable (10) is described in which the insulating sheath of the cable (10) is cut twice to form a central portion (13) between a main portion (11) and a front portion. Subsequently or concurrently with the removal of the front insulation portion (12) from the core electrical conductor (30) thereby exposing at stripped segments (30a,30b) of the electrical conductor strands (30), the central insulation portion (13) is moved away from the first insulation portion (11) but still at a non-zero distance from the exposed free ends (31) of the electrical conductor strands (30). A distal stripped portion (30b) is thus formed on the side of the third insulation portion (13) of the cable (10) remote from said first insulation portion (11), by which the electrical cable (10) can then be inserted into the barrel portion (21) of an electrical closed barrel crimp terminal (20). The central insulation portion (13) is preferably in contact with the inlet (211) of the connector barrel (21), on one side, and in contact with the main insulation portion (11) of the electrical cable (10), on the other side, when the electrical cable (10) is fully inserted into the connector barrel (21), to ensure electrical insulation of the connection. Crimping performance is enhanced, thanks to a relatively high ratio of the core conductor diameter to the barrel diameter.