Crimp Terminal Serration Array for Oxide Displacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical crimp terminals face difficulties in displacing oxide layers on conductors during crimping, especially when the terminal and conductor materials have similar strength, leading to poor electrical connections due to limited differential flow and reduced effectiveness of existing serrations.
Innovation Solution
The crimp terminal features a serration array with primary and micro-serrations of different sizes, arranged in an alternating sequence, which engages and scrapes against the conductors to displace oxide layers, even in scenarios with limited differential flow between the terminal and conductor materials, enhancing the formation of reliable metal-to-metal contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal is formed of lower-strength metals to reduce cost and improve electrical conductivity, then electrical conductivity and cost are improved, but the ability to displace oxide layer during crimping deteriorates due to similar strength between terminal and conductor materials
Solution Approach 1:
The serration array is divided into multiple discrete serrations with varying sizes (primary, secondary, and micro-serrations) arranged in sequence. This segmentation allows each serration type to perform a specific function in the oxide displacement process, with smaller micro-serrations providing the necessary scraping action even when terminal and conductor materials have similar strength characteristics.
Solution Approach 2:
Different regions of the crimp barrel interior are given different local qualities through the varied serration sizes and distributions. The micro-serrations provide localized high-frequency scraping action in regions where material flow is limited, while larger serrations provide broader engagement. This local differentiation ensures effective oxide displacement regardless of the terminal material's overall strength.
2Reliability
If the terminal and conductor materials have similar strength, then cost and electrical conductivity are improved, but differential flow during crimping is reduced, inhibiting the ability of serrations to scrape and displace oxide layer
Solution Approach 1:
The serration array segments the oxide displacement function into multiple stages with serrations of different sizes. The micro-serrations specifically address the limitation of reduced material flow by providing fine-scale scraping action that does not depend on large differential flow, thereby maintaining oxide displacement efficiency even when terminal and conductor materials have similar strength.
Solution Approach 2:
The micro-serrations provide an excessive amount of scraping action at a fine scale, compensating for the insufficient differential flow. By having more serrations with smaller dimensions that collectively provide greater surface engagement, the system ensures adequate oxide layer displacement even when the terminal material cannot flow significantly relative to the conductor material.
3Device complexity
If existing serrations are used in the crimp barrel, then the structure is simple, but the ability to displace oxide layer is insufficient when there is limited differential flow between terminal and conductor materials
Solution Approach 1:
While maintaining the basic segmented serration concept, the invention enhances reliability by dividing the serrations into multiple size categories (primary, secondary, micro) with specific functional roles. This segmentation allows the structure to remain relatively simple while significantly improving oxide displacement capability through the cumulative effect of multiple serration types working in sequence.
Solution Approach 2:
The invention changes the parameters of the serrations (size, depth, spacing, distribution) to optimize oxide displacement. By varying these parameters across different serration types in the array, the system achieves reliable electrical connection without requiring complex additional components, simply by optimizing the geometric parameters of the serrations themselves.
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
This design improves the reliability and conductivity of electrical connections by effectively scraping away oxide layers, allowing for better metal-to-metal bonding, even when the terminal and conductor materials have similar strength characteristics, resulting in lower resistance measurements and improved terminal assembly performance.
Implementation Method 1
some crimp barrels include one or more serrations that, during a crimping operation, are configured to scrape or wipe against the conductors of the wire to displace the oxide layer
Data Source
AI summary
An electrical terminal includes a crimp barrel having an interior side and an exterior side. The interior side of the crimp barrel defines a channel that extends along a longitudinal axis. The crimp barrel is configured to mechanically hold and electrically connect to one or more electrical conductors of an electrical device received in the channel. The crimp barrel includes multiple primary serrations spaced apart along the longitudinal axis. The primary serrations are groove-shaped recesses formed along the interior side. Adjacent primary serrations are separated from one another by a band. The crimp barrel further includes at least one micro-serration on the band. Each micro-serration is a groove-shaped recess formed along the interior side that has a smaller size relative to the primary serrations.