Crimp Connection Terminal Void Structure
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Solution Overview
Problem
Existing crimp connection terminals face challenges in reliably securing and maintaining a strong connection with fiber wires due to the poor extensibility and plasticity of copper-plated conductor portions, leading to issues with conductivity and ease of disconnection.
Innovation Solution
A crimp connection terminal with a unique conductor crimping portion featuring U-shaped crimping pieces and a void structure that allows for strong crimping and fixation of the conductor portion, utilizing a two-layered metal plate structure with a void that reduces to a flat shape under crimping force, ensuring a secure and gap-free connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional single-layer crimping structure is used, then the device complexity is reduced, but the fixing force and connection reliability are insufficient for fiber wire conductor portions
Solution Approach 1:
The crimping portion is divided into multiple crimping pieces (first crimping piece and second crimping piece) that are arranged adjacently. Each crimping piece has its own void structure, allowing independent deformation and compression of the conductor portion from multiple directions, thereby improving connection reliability without requiring a completely new complex structure
Solution Approach 2:
The void structure is formed by folding back the upper layer plate to create a nested configuration where the folded-back portion forms a cavity within the crimping piece structure. This nested void space allows the conductor portion to be compressed and deformed effectively during crimping, enhancing fixing force while maintaining structural integration
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 solution enables reliable crimping and fixing of twisted core wires, enhancing the fixing force and conductivity of the fiber wire connection while preventing disconnection, even under pulling forces.
Implementation Method 1
when a strong crimping force is applied in a crimping process of a conductor portion of an electric wire, upper ends of the crimping pieces (3c, 3d) are closed and the void (3g) is reduced to be flat so that the conductor portion is firmly tightened and fixed without a gap
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
In a conductor crimping portion 3, a pair of crimping pieces 3c and 3d having a two-layer structure of an upper layer plate 3a and a lower layer plate 3b connecting the upper layer plate 3a is raised in a U-shape from both sides of a bottom portion 3e. A void 3g is formed inside a folded-back portion of the upper layer plate 3a from the lower layer plate 3b. In the conductor crimping portion 3, the crimping pieces 3c and 3d have a two-layer structure, and a conductor portion is elastically fixed and connection becomes strong due to the presence of the void 3g.