Crimp Terminal Structure to Retain Anti-Corrosive Material
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Solution Overview
Problem
In the manufacturing of terminal-equipped electric wires, there is a risk that the anti-corrosive material may drip down from the side wall of an intermediate portion when the electric wire is crimped with a size smaller than optimized, leading to ineffective corrosion protection.
Innovation Solution
The terminal-equipped electric wire design includes a crimp terminal with a conductor crimp portion, a coating fastening portion, and an intermediate portion where the outer surfaces of the first and second fastening pieces contact each other, ensuring that the side wall of the intermediate portion remains upright and prevents the anti-corrosive material from dripping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimping is performed while overlapping the first fastening piece on the distal end portion of the second fastening piece, then the coating fastening portion can securely fasten the coating, but the side wall of the intermediate portion may roll inward and collapse, causing the anti-corrosive material to drip down
Solution Approach 1:
The coating fastening portion is divided into a first fastening piece and a second fastening piece that are arranged side by side rather than overlapping. This segmentation prevents the side wall from rolling inward while maintaining secure fastening of the coating through the combined action of both fastening pieces.
Solution Approach 2:
The fastening pieces are arranged in a lateral direction rather than overlapping in the longitudinal direction. This dimensional change from vertical stacking to horizontal arrangement eliminates the side wall collapse issue while preserving fastening functionality.
2Adaptability or versatility
If the electric wire size is smaller than optimized for the crimp terminal, then smaller wires can be accommodated, but the side wall of the intermediate portion may collapse inward during crimping
Solution Approach 1:
The coating fastening portion is segmented into two separate fastening pieces arranged side by side. This configuration provides better support to the intermediate portion side wall during crimping of smaller wires, preventing collapse while maintaining adaptability to different wire sizes.
Solution Approach 2:
The side wall of the intermediate portion is designed with enhanced local structural quality to resist inward rolling during crimping. The side wall maintains its shape through proper thickness and rigidity, ensuring stability when accommodating smaller electric wires.
3Object-affected harmful factors
If the anti-corrosive material is applied to the intermediate portion, then corrosion protection is provided, but the material may drip down from the side wall if the side wall collapses
Solution Approach 1:
The coating fastening portion is segmented into two side-by-side fastening pieces that prevent side wall collapse. This structural configuration ensures the intermediate portion maintains its shape, allowing the anti-corrosive material to be retained properly without dripping down.
Solution Approach 2:
Instead of relying on the side wall to contain the anti-corrosive material after application, the design prevents side wall collapse from the beginning through the side-by-side fastening piece configuration. This inverted approach ensures material retention by maintaining structural integrity rather than attempting to contain the material after application.
Data Source
AI summary
A terminal-equipped electric wire includes an electric wire including a conductor and an insulative coating that covers the conductor, and a crimp terminal including a conductor crimp portion that crimps the conductor, a coating fastening portion that includes a first fastening piece and a second fastening piece and fastens the insulative coating of the electric wire by the first fastening piece and the second fastening piece, and an intermediate portion that connects the conductor crimp portion and the coating fastening portion, wherein an outer surface of the first fastening piece and an outer surface of the second fastening piece contact with each other, and an upper end of a side wall of the intermediate portion is higher than an upper end of the conductor.