Interlocking Serration Crimp Terminal for Wire Pull-Out Resistance
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Solution Overview
Problem
Existing crimp terminals fail to provide sufficient resistance to pull-out forces under high loads, leading to potential damage of the electrical contact and reduced connector lifetime.
Innovation Solution
A crimp terminal design featuring serrations on both inner and outer surfaces of the crimping segment, with interlocking serrations providing a form-fit connection and increased structural strength to resist pull-out forces, while also cutting through oxide layers for improved electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional crimp terminals with single-surface serrations are used, then the structure is simple, but the resistance to pull-out force is insufficient under high loads
Solution Approach 1:
The patent applies dimensionality change by transitioning from single-surface serrations to multi-surface serrations. Specifically, serrations are added to both the inner and outer surfaces of the crimp terminal walls, and further extended to the top and bottom surfaces, creating a three-dimensional interlocking structure that significantly enhances resistance to pull-out forces while maintaining manufacturing feasibility
Solution Approach 2:
The patent implements nesting by creating interlocking serration patterns where serrations on opposite walls are positioned to engage with each other. The first wall has serrations at specific positions that interlock with corresponding serrations on the second wall, forming a nested, interlocked structure that prevents wire movement under load
2Stability of the object's composition
If crimp terminals provide sufficient mechanical locking, then wire stability improves, but electrical contact quality may be compromised due to excessive deformation
Solution Approach 1:
The patent applies local quality by differentiating the function of different serration surfaces. The inner surface serrations are optimized for electrical contact quality with smaller, finer teeth that remove oxide layers without excessive deformation, while the outer surface and top/bottom serrations are designed for mechanical locking with larger, more robust features. This localized differentiation allows simultaneous optimization of both electrical and mechanical performance
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
Enhances mechanical and electrical stability by increasing resistance to pull-out forces and ensuring reliable electrical contact, even in the presence of oxide layers, thereby extending the connector's lifespan.
Implementation Method 1
These serrations are used for cutting into the surface of the wire to remove the presence of oxide layers
Implementation Method 2
The first side wall has a first serration on the second surface. The second side wall has a pair of second serrations on the second surface... in a crimped state, a portion of the first serration is positioned between a pair of portions of the second serrations
Data Source
AI summary
A crimp terminal includes a crimping segment having a base, a first side wall extending from the base, and a second side wall extending from the base opposite the first side wall. The crimping segment has a first surface adapted for arranging a wire thereon along a longitudinal axis and a second surface opposite the first surface. The first side wall has a first serration on the second surface. The second side wall has a pair of second serrations on the second surface. The first serration is displaced from the second serrations along the longitudinal axis and, in a crimped state, a portion of the first serration is positioned between a pair of portions of the second serrations along the longitudinal axis.