Crimping Connector Fusion Method for Uniform Wire Crushing
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Solution Overview
Problem
Existing methods for connecting electrical conductor wires using crimping connectors often result in uneven crushing, leading to incomplete electrical connections and reduced mechanical tensile strength due to variations in crushing degrees across the connector, with the center parts being over-crushed and end parts being under-crushed.
Innovation Solution
A method involving temporary crimping to suppress expansion at the ends of the crimping connector, followed by fusing with electrodes to ensure even deformation and discharge of enamel coating, enhancing the crimping degree at the ends and achieving stable electrical connections while increasing mechanical tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flat pressurizing surface electrode is used to crush the crimping connector in the conventional fusing process, then the center part of the connector is effectively crushed, but the end parts are insufficiently crushed, resulting in incomplete electrical connections
Solution Approach 1:
The patent applies local quality by designing the electrode with different surface characteristics at different locations. The end portions of the electrode have a curved pressurizing surface that concentrates pressure on the end parts of the connector, while the center portion has a flat surface. This creates locally adapted pressure distribution to achieve uniform crushing throughout the connector.
Solution Approach 2:
The patent employs asymmetry by making the electrode's pressurizing surface asymmetric rather than uniformly flat. The curved surfaces at the ends and flat surface at the center create an asymmetric pressure distribution pattern that compensates for the natural tendency of pressure to concentrate at the center, thereby achieving uniform crushing across the entire connector length.
2Manufacturing precision
If the electrode positions and current strength are adjusted to uniformly apply force to all conductor wires, then crushing uniformity can be improved, but the process complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the electrode with an asymmetric pressurizing surface configuration before the crushing operation. This geometric pre-programming embeds the pressure distribution strategy into the electrode structure itself, eliminating the need for complex real-time adjustments of electrode positions or current strength during the actual crushing process.
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
This approach ensures complete electrical connections with improved mechanical strength by uniformly deforming the conductor wires, eliminating airspace and enhancing coherence within the connector, thereby stabilizing the resistance value and tensile strength.
Implementation Method 1
the electrode bars 19 and 20 are electrified to remove coating from the coated conductor wires
Implementation Method 2
a connection part, which is then pinched with electrodes for pressurization and electrification, thereby causing the above crimping terminals along with the enamel-coated conductor wire to be heated and crimped
Data Source
AI summary
After melted enamel coating is discharged, a fusion process of electrical wire-to-wire connection is carried out inside a crimping connector. In the conductor connection method based on the fusion process, a plurality of enamel-coated conductor wires are inserted in the crimping connector prior to the start of the fusion process. Further, a temporary crimping process that provides the crimping connector a temporary crimping by mechanical pressurizing means is also performed. Addition of force at both end parts or either end part of the cross-section orthogonal to the axis of the above crimping connector may cause expansion, which needs to be suppressed with external force. At the same time, the cross-sectional areas corresponding to both end parts or either end part should preferably be as small as possible. The temporary crimping is applied to the crimping connector for this purpose.