Crimp Terminal Serration Design for Wire Adhesion
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Solution Overview
Problem
The existing crimp terminals with serrations on the crimping surface face issues with non-uniform crimping forces, leading to deformation of serrations and inefficient adhesion among strands, resulting in increased electric resistance at the crimping positions.
Innovation Solution
A crimp terminal design featuring first serrations in regions with small crimping forces and second serrations smaller than the first in regions with larger forces, ensuring effective stretch and adhesion of the core wire strands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform serrations are provided all over the core-wire crimping section, then the structure is simple and easy to manufacture, but the serrations in regions with large crimping forces are deformed into oval shapes, reducing their effectiveness in stretching and adhering the core wire strands
Solution Approach 1:
The patent applies different serration sizes to different regions of the core-wire crimping section based on the local crimping force distribution. First serrations (larger) are provided in regions with smaller crimping forces, while second serrations (smaller) are provided in regions with larger crimping forces. This local differentiation ensures that serrations maintain their circular shape and stretching effectiveness in high-force regions while still providing adequate adhesion in low-force regions.
2Strength
If all serrations are made large to ensure effective stretch in all regions, then adhesion among strands is improved, but serrations in regions with large crimping forces are excessively deformed, reducing their effectiveness
Solution Approach 1:
The patent differentiates serration sizes according to the local mechanical conditions. In regions F0, F1, and F2 where large crimping forces are applied, smaller second serrations are used to maintain their circular shape and stretching function. In other regions where crimping forces are smaller, larger first serrations are used to provide sufficient adhesion. This local optimization ensures both adhesion strength and serration reliability across the entire crimping section.
3Ease of operation
If crimping forces are applied uniformly, then the crimping process is simple to control, but non-uniform force distribution occurs naturally during swaging, causing serration deformation in high-force regions
Solution Approach 1:
The patent acknowledges the non-uniform crimping force distribution during swaging and compensates for it through local serration differentiation. By providing smaller second serrations in regions F0, F1, and F2 where large forces are applied, the design ensures these serrations maintain their circular shape and stretching effectiveness. The larger first serrations in low-force regions provide adequate adhesion without excessive deformation. This approach maintains simple crimping process control while ensuring serration shape maintenance through localized structural optimization.
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 reduces electric resistance at the crimping position by promoting efficient adhesion and stretch of the core wire strands, improving conduction characteristics without increasing costs or altering the core wire material.
Implementation Method 1
there are a 'region to which a large crimping force is applied' and a 'region to which a small crimping force is applied' on the core-wire crimping section 116
Implementation Method 2
serrations 118 provided in the 'region to which a large crimping force is applied' are deformed into an oval shape due to large stretch caused by the rolling
Data Source
AI summary
A crimp terminal including a core-wire crimping section (16) for crimping a core wire of an electric wire including a plurality of strands includes serrations (18a, 18b) provided on a surface where the core wire of the core-wire crimping section (16) is to be crimped, small serrations (18b) are provided in a region to which a large crimping force is applied during a swaging and crimping process, and large serrations (18a) are provided in a region to which a small crimping force is applied.