Crimp Connection Terminal With Stacked Plates And Biting Edges
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Solution Overview
Problem
The miniaturization of connection terminals has led to reduced thickness of conductive metal plates, limiting crimping force and increasing the likelihood of conductor portions falling out, and existing solutions with stacked structures complicate production and do not provide sufficient locking force.
Innovation Solution
A crimp connection terminal with a U-shaped crimping tab structure formed by punching, stamping, and folding a conductive metal plate, featuring a stacked structure with a top layer plate having a punched long hole and recessed portion, which enhances crimping force through two-step biting edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of conductive metal plate is decreased to achieve miniaturization, then the size of connection terminal is reduced, but the crimping force of conductor crimping portion is limited
Solution Approach 1:
The invention transitions from a single-layer structure to a stacked multi-layer structure, adding the dimension of layering to increase crimping force without increasing the overall footprint of the terminal. The stacked plates create multiple crimping surfaces that collectively provide sufficient locking force despite each individual plate being thin.
Solution Approach 2:
The invention uses multiple conductive metal plates stacked together to form a composite structure. This composite approach combines the thin plates to achieve both miniaturization (through individual plate thinness) and sufficient crimping force (through the cumulative effect of multiple layers working together).
2Force
If a two-layer structure with stacked plates is used to increase crimping force, then the securing of conductor portion is improved, but the terminal production process is complicated and the number of parts increases
Solution Approach 1:
The invention merges multiple functional elements into a single integrated terminal structure. The stacked plates are formed as one unified component with conductor crimping portions, insulation crimping portions, and connection portions all integrated together, simplifying production despite the multi-layer construction.
Solution Approach 2:
The stacked plate structure serves multiple functions simultaneously: it provides mechanical support, electrical conduction, conductor crimping, and insulation crimping. This multi-functionality reduces the need for separate components, simplifying the overall production process while maintaining sufficient crimping force.
3Reliability
If grooves or holes are provided in the bottom portion to secure conductor portion, then the locking mechanism is enhanced, but sufficient locking force cannot be obtained
Solution Approach 1:
The invention segments the crimping function across multiple plates, with each plate contributing to the overall locking force. The conductor crimping portions are divided among the stacked plates, creating multiple contact points and distributed locking mechanisms that collectively provide sufficient securing force.
Solution Approach 2:
The invention adds the vertical dimension through stacked plates, creating multiple levels of crimping engagement. Instead of relying on a single plane with grooves or holes, the multi-layer structure provides vertical stacking of crimping surfaces, dramatically increasing the total locking force available to secure the conductor portion.
Data Source
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AI summary
A small crimp connection terminal is obtained whereby a conductor portion of an electric wire can be reliably crimped in a conductor crimping portion. The crimp connection terminal is formed by punching and folding a conductive metal plate (1). The crimp connection terminal is provided with a male connection portion (2) at the front, a conductor crimping portion (3) at the middle, and a cover crimping portion (4) at the back. In the conductor crimping portion (3), side portions (3a, 3b) are folded into a bottom layer plate (3c) and a top layer plate (3d), and edges of the side portions (3a, 3b) are abutted against each other to form a joint (3g). Additionally, three long groove-like punched long holes (3i to 3k), for example, are provided in an oblique direction with respect to a longitudinal direction of the crimp connection terminal in a bottom portion (3h) of the top layer plate (3d). A shallow round recessed portion (31) is formed in the surface of the punched long hole (3i) by stamping. Edges (3m) of this recessed portion (31) and new edges (3n') formed by edges (3n) of the punched long hole (3i), obtained by the punching, being pushed inward by the stamping are formed in two steps.