Crimp Terminal Structure for Small-Diameter Wire Strength and Conductivity
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Solution Overview
Problem
The increasing demand for smaller diameter electric wires in motor vehicles poses challenges in achieving both strong connection strength and low electric resistance at the crimp terminal connections, especially as wire diameters approach 0.35 sq mm or less.
Innovation Solution
A terminal-equipped electric wire design that includes a conductive wire crimp part with distinct electric wire holding and conductive parts, allowing for varying compression rates to achieve optimal connection strength and resistance, even with small-diameter wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electric wire diameter is reduced to meet smaller component requirements, then the wire diameter decreases, but it becomes difficult to maintain both connection strength and electric resistance specifications at the crimp terminal
Solution Approach 1:
The conductive wire crimp part is segmented into two distinct functional regions: an electric wire holding part for mechanical strength and a conductive part for electrical conduction. This segmentation allows each part to be optimized independently for its specific function, enabling small-diameter wires to achieve both strength and conductivity requirements simultaneously.
Solution Approach 2:
Different regions of the conductive wire crimp part are given different local qualities: the electric wire holding part has properties optimized for mechanical gripping strength, while the conductive part has properties optimized for electrical conductivity. This local differentiation resolves the contradiction by allowing each region to excel at its specific function without compromising the other.
2Strength
If the compression rate at the conductive wire crimp part is increased to improve connection strength, then connection strength improves, but the conductor may fracture and electric resistance increases
Solution Approach 1:
The crimping process is segmented into two distinct compression zones within the conductive wire crimp part. The electric wire holding part applies higher compression for strength, while the conductive part applies lower compression to maintain conductivity. This segmentation resolves the contradiction by spatially separating the conflicting compression requirements.
Solution Approach 2:
Different compression rates are applied to different local regions of the crimp part. The electric wire holding part receives high compression locally to achieve strong mechanical bonding, while the conductive part receives lower compression locally to preserve electrical conductivity. This local quality differentiation allows both strength and low resistance requirements to be satisfied simultaneously.
3Ease of manufacture
If conventional crimping methods are used for small-diameter wires, then manufacturing process remains simple, but it becomes difficult to satisfy both connection strength and electric resistance specifications
Solution Approach 1:
The terminal structure is segmented to include both the electric wire holding part and conductive part as integral components of the conductive wire crimp part. This design allows conventional single-step crimping equipment to be used while achieving differentiated compression effects, maintaining manufacturing simplicity while improving specification compliance.
Solution Approach 2:
The electric wire holding part and conductive part are merged into a single integrated conductive wire crimp part structure. This merging allows both functions to be achieved in one crimping operation without requiring separate manufacturing steps, thus maintaining ease of manufacture while meeting precise specification requirements.
Data Source
AI summary
A terminal-equipped electric wire includes a terminal and a coated conductive wire, which are electrically connected to each other. A crimp part of the terminal is crimped to the coated conductive wire, and has a conductive wire crimp part, which is crimped to a conductive wire that is exposed from a coating on the front-end side of the coated conductive wire, and a coating crimp part, which is crimped to the coating of the coated conductive wire. On the front-end side (terminal body side) of the conductive wire crimp part, an electric wire holding part, which applies a relatively strong holding force on the conductive wire, is provided, On the rear-end side (coating crimp part side) of the conductive wire crimp part, a conductive part for achieving conduction with the conductive wire is formed.