Crimp Terminal Water Stop Protrusion Design
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Solution Overview
Problem
Conventional crimp terminals experience deterioration in waterproof performance due to the squeezing out of water stop sheets or insulating resin layers during the swaging process, which compromises the electrical connection and durability of the crimped area.
Innovation Solution
A crimp terminal design featuring a water stop member pasted on the inner wall surface of the electric wire connecting portion, with a protruding portion and groove configuration that locks the core wire in place, preventing water entry and maintaining the integrity of the water stop area after crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a water stop sheet or insulating resin layer is used to seal the gap between the barrel piece and electric wire, then waterproof performance is improved, but the water stop material is squeezed out during swaging which deteriorates waterproof performance
Solution Approach 1:
The protruding portion is formed on the inner wall surface of the core wire crimp portion before crimping occurs. This preliminary structural feature prevents the water stop material from being squeezed out during the crimping process by providing a physical barrier that locks the material in place, thereby maintaining waterproof performance throughout the swaging operation.
Solution Approach 2:
The inner wall surface of the core wire crimp portion is given a different local structure (protruding portion) compared to the rest of the surface. This localized structural modification creates a specific region that prevents water stop material displacement while maintaining the overall crimping function, resolving the contradiction between sealing effectiveness and material stability.
2Strength
If the electric wire is compressed by the barrel piece during swaging, then electrical connection is improved, but the core wire stretches in the axial direction which may compromise waterproof sealing
Solution Approach 1:
The protruding portion is prepared in advance on the inner wall surface before crimping. When crimping occurs and the core wire stretches axially, this pre-formed protruding portion engages with the water stop material to prevent its displacement, thereby maintaining waterproof sealing even while allowing the necessary wire compression and stretching for strong electrical connection.
Solution Approach 2:
The inner wall surface is modified locally with a protruding portion that specifically addresses the waterproofing concern during axial stretching, while the rest of the crimping structure maintains its compression function for electrical connection. This localized structural differentiation resolves the contradiction between connection strength and sealing reliability.
Data Source
AI summary
A crimp terminal includes: a terminal fitting having a terminal connecting portion electrically connected to a counterpart terminal and an electric wire connecting portion electrically connected by crimping to an end portion of an electric wire placed on an inner wall surface thereof; and a second water stop portion that is pasted on the inner wall surface of the electric wire connecting portion before crimping and that, after crimping, forms a second water stop area capable of suppressing water entry between the electric wire connecting portion and the core wire from the terminal connecting portion side with respect to the distal end position of the core wire at the distal end of the electric wire. The electric wire connecting portion has a core wire crimp portion crimped on the core wire at the distal end of the electric wire.