Crimp Terminal Seal Member Segmentation for Aluminum Wire Waterproofing

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Solution Overview

Problem

Conventional crimp terminals for aluminum core wires face manufacturing difficulties due to the narrow installation range of seal members, which can lead to inadequate waterproofing against dissimilar metal corrosion.

Innovation Solution

A crimp terminal design featuring a barrel section with a bottom plate and inner and outer barrel pieces, equipped with a sealing member formed from an adhesive gel sheet, which is affixed in a divided state across multiple regions to ensure effective sealing and conduction, alleviating manufacturing challenges while maintaining high waterproofness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a seal member is provided to surround the contact portion between the barrel section and aluminum core wire, then waterproofness against dissimilar metal corrosion is improved, but manufacturing difficulty increases due to narrow installation range

Engineering Contradiction:

ImprovewaterproofnessVSAvoidmanufacturing difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The seal member is divided into multiple separate seal portions (first seal portion, second seal portion, third seal portion) that are affixed to different regions of the barrel section. This segmentation allows each seal portion to be independently positioned and attached, making it easier to manufacture while still providing comprehensive sealing coverage around the contact portion between the aluminum core wire and barrel section.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An adhesive gel sheet is used as an intermediary material to affix the seal portions to the barrel section. This adhesive layer facilitates the sealing function by creating a reliable bond between the seal portions and the barrel section, ensuring waterproofness while simplifying the manufacturing process through easy application.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the seal member is affixed in a divided state across multiple regions, then manufacturing complexity is reduced, but sealing effectiveness may be compromised

Engineering Contradiction:

Improvemanufacturing complexityVSAvoidsealing effectiveness

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple seal portions positioned at different locations (first region, second region, third region) work together to provide comprehensive sealing. The combined effect of these distributed seal portions ensures that the entire contact portion is protected from moisture, maintaining sealing effectiveness equivalent to or better than a single continuous seal member.

Inventive Principle:

Principle #5Merging (Combining)

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 crimp terminal achieves relaxed manufacturing complexity and secure waterproofness at the contact portion with aluminum core wires, ensuring reliable conduction and corrosion prevention.

Implementation Method 1

a seal member formed from an adhesive gel sheet

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS10505287B2Crimp terminal and crimp terminal manufacturing method

Publication Date: 2019.12.10 YAZAKI CORP

AI summary

The present invention makes production less difficult and ensures the waterproofness of a site of contact with an aluminum core wire. According to the present invention, a barrel section of a crimp terminal: has an inner barrel piece and an outer barrel piece; and an inner surface thereof is provided with a plurality of concave sections. A seal member that is formed from an adhesive gel sheet is affixed across a first region, a second region, and a third region and, after crimping, seals: between the inner barrel piece and the outer barrel piece; between a covered portion and the barrel section; and an opening that is on a terminal section side of the barrel section. The seal member is divided over the course of a path that goes from the second region through the first region to the third region.