Crimp Terminal With Variable Barrel Intervals
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Solution Overview
Problem
Conventional crimp terminals often fail to be appropriately crimped onto wires, leading to decreased crimping strength and waterproof performance due to clearance gaps and improper crimping.
Innovation Solution
A crimp terminal design with a wire connection portion featuring a bottom wall and side wall portions that widen at the ends, allowing for precise crimping onto both the core wire and covering, using a mold to bend the side walls inward and ensure proper contact and crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the crimp terminal uses a conventional uniform barrel piece design, then the structure is simple, but crimping strength decreases and clearance gaps are generated
Solution Approach 1:
The barrel piece is divided into multiple segments along the longitudinal direction, with each segment having a different interval between side wall portions. This segmentation allows the crimp terminal to adapt to different wire diameters and achieve proper crimping strength without creating clearance gaps, while maintaining reasonable structural simplicity.
Solution Approach 2:
Different portions of the barrel piece are designed with different interval characteristics - the first portion has a first interval, the second portion has a second interval, and the third portion has a third interval. This local quality variation ensures optimal contact and crimping force distribution along the wire, preventing clearance gaps and enhancing crimping strength.
2Reliability
If the barrel piece portions interfere with each other during crimping, then the structure may be simple, but waterproof performance decreases
Solution Approach 1:
The barrel piece is pre-formed with specific interval variations in different portions before the crimping process. This preliminary action ensures that during crimping, the side wall portions will not interfere with each other, preventing the reversal phenomenon and ensuring proper waterproof performance without complicating the manufacturing process.
3Reliability
If the interval between side wall portions is uniform, then the manufacturing is simple, but clearance gaps are generated reducing waterproof performance
Solution Approach 1:
The barrel piece is designed with non-uniform intervals between side wall portions - the first portion has a first interval, the second portion has a second interval, and the third portion has a third interval. This local quality variation eliminates clearance gaps that would compromise waterproof performance, while the intervals are designed to be practically manufacturable without excessive complexity.
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 design ensures stable crimping and enhanced waterproof performance by preventing interference and reversal of the barrel piece portions, maintaining crimping strength and water stop effectiveness.
Implementation Method 1
a second mold configured to come into contact with outer wall surfaces of the pair of side wall portions while relatively moving with respect to the first mold, and bend the pair of side wall portions inward to crimp the pair of side wall portions onto the wire
Data Source
AI summary
A crimp terminal includes a wire connection portion including a bottom wall portion, and a pair of side wall portions. The wire connection portion includes a core wire crimping portion provided on one end side, and to be crimped onto a core wire of a wire, and a covering crimping portion provided on another end side, and to be crimped onto a covering of the wire, and integrally covers the core wire and the covering. In the core wire crimping portion before crimping, an interval between outer wall surfaces of the pair of side wall portions is widest at an end portion on the covering crimping portion side, and in the covering crimping portion before crimping, the interval is widest at an end portion on the core wire crimping portion side.