Crimping Terminal Beads for Thermal Rigidity
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Solution Overview
Problem
Conventional crimping terminals experience increased contact resistance and reduced rigidity due to thermal shock, leading to degradation in electric connection performance, especially when serrations are formed on the inner surface, causing the terminal to stretch and lose rigidity, resulting in gaps between the terminal and the electric cable.
Innovation Solution
The crimping terminal incorporates beads formed on the outer surface of the conductor crimping portion with staggered, circular recesses as serrations, which improve rigidity and prevent excessive stretching, maintaining contact pressure and reducing thermal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If serrations are formed on the inner surface of the conductor crimping portion, then the connection state between the terminal and electric cable is improved, but the terminal stretches in its axial direction and rigidity is reduced
Solution Approach 1:
The invention applies local quality by forming beads at specific locations (both ends of the conductor crimping portion) rather than uniformly across the entire surface. This localized reinforcement provides rigidity where needed while preserving the serration structure for electrical connection where required, thus resolving the contradiction between connection quality and structural rigidity.
2Volume of moving object
If the thickness of the terminal is decreased to reduce size, then the compactness is improved, but the rigidity of the conductor crimping portion is reduced causing excessive deformation under thermal shock
Solution Approach 1:
The invention segments the conductor crimping portion by dividing it into multiple sections with beads formed at both ends. This segmentation creates discrete reinforcement zones that provide structural rigidity without requiring increased overall thickness, allowing the terminal to maintain compact dimensions while resisting thermal deformation through strategically placed rigid segments.
3Volume of moving object
If the terminal is made thinner to decrease size, then the compactness is improved, but the contact resistance increases due to insufficient rigidity under thermal shock
Solution Approach 1:
The beads are formed in advance during the terminal manufacturing process, creating preliminary reinforcement structures that prevent deformation before thermal shock occurs. This preliminary action ensures that the conductor crimping portion maintains its shape and contact pressure even when the terminal is made thinner, thereby preserving low contact resistance under thermal conditions.
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 design stabilizes contact resistance by enhancing the rigidity of the conductor crimping portion, suppressing deformation and maintaining initial hardness even after thermal shock, ensuring a strong and reliable electrical connection.
Implementation Method 1
the beads improve the rigidity of a portion from a bottom plate of the conductor crimping portion to a conductor crimping tab thereof
Implementation Method 2
the conductor crimping portion repeatedly expands and contracts as illustrated in FIG. 1(a) and FIG. 1(b) like a breathing operation
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3(a)~3(d)
AI summary
A crimping terminal includes a conductor crimping portion which is connected to an electric cable so as to crimp the electric cable. The conductor crimping portion includes a bottom plate on which a conductor is placed and a pair of conductor crimping tabs which is provided on both sides of the bottom plate. The conductor crimping portion includes serrations that are formed at least a part of the inner surface thereof and retains the conductor of the electric cable inside the conductor crimping portion and at least one bead that protrudes from the inner surface.