Crimp Terminal Sealed Tip and Transition Design
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Solution Overview
Problem
Crimp terminals formed of copper and connected to aluminum-based electrical wires face corrosion issues due to contact with moisture, leading to electrical failures and reduced durability, especially when used in harsh vehicle environments.
Innovation Solution
A crimp terminal design featuring a tubular electrical wire connection portion with a sealed tip and a transition portion formed by superimposing and bending plate material, enhancing the section modulus and preventing moisture infiltration, while using copper-based materials for the terminal and aluminum-based materials for the conductor to reduce weight and prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If copper-based crimp terminal is used with aluminum-based conductor, then weight is reduced, but electrical corrosion occurs due to contact between dissimilar metals
Solution Approach 1:
A resin coating is applied to the aluminum conductor to serve as an intermediary layer between the dissimilar metals. This coating prevents direct contact between aluminum and copper, eliminating the galvanic corrosion pathway while allowing electrical connection to function. The resin acts as a protective mediator that maintains electrical conductivity while preventing harmful electrochemical reactions.
Solution Approach 2:
The solution employs a composite structure where the aluminum conductor is coated with resin material, creating a multi-layer composite. This composite construction combines the lightweight properties of aluminum with the protective and insulating properties of resin, achieving both weight reduction and corrosion prevention simultaneously.
2Reliability
If resin coating is applied to prevent corrosion, then electrical corrosion is prevented, but manufacturing complexity increases
Solution Approach 1:
The resin coating process is designed to be self-applying or self-curing, where the coating material automatically forms the protective layer without requiring complex additional manufacturing steps. This may involve dip-coating, spray-coating, or self-assembling molecular structures that simplify the overall manufacturing process while maintaining effective corrosion protection.
3Weight of moving object
If aluminum-based conductor is used, then weight is reduced, but contact corrosion occurs in harsh environments with moisture
Solution Approach 1:
A thin resin film or coating is applied to the aluminum conductor surface, creating a flexible protective barrier that conforms to the conductor shape. This thin film prevents moisture penetration while maintaining the lightweight advantage of aluminum, as the coating adds minimal weight compared to the bulk aluminum conductor.
Solution Approach 2:
The solution employs a composite structure where the aluminum conductor is coated with resin material, creating a multi-layer composite. This composite construction combines the lightweight properties of aluminum with the protective and insulating properties of resin, achieving both weight reduction and corrosion prevention simultaneously.
Data Source
Figure 1(A)~1(F)
Figure 2(A)~2(D)
Figure 3(A)~3(E)
AI summary
A crimp terminal that can maintain excellent water-stop performance over a long term and is enhanced in joint strength between a fitting portion and a covered electrical wire connection portion. The crimp terminal has a fitting portion 20 at a tip thereof and an electrical wire connection portion 30 at a rear end thereof, the electrical wire connection portion 30 is configured in a tubular shape, a tip of the tube is crushed to be superimposed and closed, and a portion between the fitting portion and the electrical wire connection portion is formed by superimposing and bending two or more sheets of a plate material.