Crimp Terminal Wire with Stepped Conductor Ends
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Solution Overview
Problem
The existing electric wire with a crimp terminal is difficult to connect metal element wires arranged in a radial direction due to the troublesome process of cutting them in alignment along the circumferential direction.
Innovation Solution
The electric wire with a crimp terminal features terminal surfaces of metal element wires cut in alignments to extend further from one side portion, forming steps or inclined end surfaces, or having metal element wires folded back, allowing for improved connection stability without making the fitting work troublesome.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal element wires are cut in alignment along the circumferential direction to connect radial wires to the crimp terminal, then connection stability is improved, but the fitting work becomes troublesome and complex
Solution Approach 1:
The patent applies preliminary action by pre-forming the conductor portion with an inclined end surface or stepped configuration before the crimping operation. This preliminary shaping of the conductor allows the crimp terminal to be directly attached without requiring separate alignment cutting operations, thus improving connection stability while simplifying the fitting process
Solution Approach 2:
The conductor portion is segmented into multiple metal element wires with different lengths, arranged in a stepped or inclined configuration. This segmentation allows each wire to be independently positioned and connected to the crimp terminal, improving connection reliability while the overall structure remains simple to manufacture
2Reliability
If metal element wires are arranged in radial direction inside the conductor portion, then electrical conductivity is improved, but it becomes difficult to connect these wires to the crimp terminal
Solution Approach 1:
The patent transitions from a two-dimensional radial arrangement to a three-dimensional stepped or inclined configuration. By arranging metal element wires at different lengths and positions in space, the design maintains radial conductivity while enabling direct access to the crimp terminal, thus improving both electrical performance and ease of connection
Solution Approach 2:
The conductor portion employs an asymmetric design with an inclined end surface or stepped structure where metal element wires have different lengths. This asymmetric arrangement allows wires in the radial direction to be differentially exposed, making them accessible for crimp terminal connection while maintaining optimal electrical conductivity
Data Source
AI summary
An electric wire with a crimp terminal which can improve a connection stability between a crimp terminal and the electric wire without making a fixing work of the crimp terminal troublesome is provided. In an electric wire with a crimp terminal in which an outer peripheral surface of a conductor portion into which a plurality of metal element wires is bundled together is covered with an insulating sheath portion into an electric wire, and the conductor portion of a terminal portion of the electric wire is exposed, and a conductor crimping portion of the crimp terminal is crimped onto the exposed conductor portion, the terminal surfaces of the plurality of metal element wires are cut in alignments so that the metal element lines extend more as the metal element lines are farther from one side portion side of the exposed conductor portion in a radial direction.