Crimping Terminal Joint Width Control
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Solution Overview
Problem
Conventional crimping terminals often deform during the crimping process, leading to swelling of the joint portion, which can damage the cavity when accommodated, resulting in inefficiencies and potential damage.
Innovation Solution
A manufacturing method for crimping terminals that includes a terminal supply step, a support step using a first mold, a crimp step with a second mold, and a regulation step where the joint portion's width is controlled by a regulation portion to prevent excessive widening, ensuring it does not exceed the width of the terminal connection portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the wire connection portion is crimped onto the wire by deforming it, then the crimping strength is improved, but the joint portion deforms and swells outward causing damage to the cavity
Solution Approach 1:
The regulation portion is positioned to preemptively counteract the outward swelling of the joint portion during crimping. By applying opposing force through the regulation portion's wall surfaces, the harmful deformation is prevented before it can damage the cavity, while still allowing sufficient crimping force to be applied to the wire connection portion
Solution Approach 2:
The regulation portion is strategically positioned to apply localized constraint only to the joint portion, while the wire connection portion remains free to deform adequately for proper crimping. This selective local control allows the wire connection portion to achieve necessary deformation for strength while the joint portion maintains its shape
2Ease of manufacture
If the joint portion is allowed to deform freely during crimping, then the crimping process is simpler, but the deformed portion damages the inside of the cavity
Solution Approach 1:
The regulation portion acts as an intermediary element between the crimping terminal and the cavity. It mediates the crimping process by selectively constraining the joint portion while allowing the wire connection portion to deform, thereby preventing damage to the cavity without complicating the overall crimping process
3Productivity
If the width of the joint portion is not regulated, then the crimping operation is faster, but the joint portion becomes wider than the terminal connection portion causing accommodation problems
Solution Approach 1:
The regulation portion is pre-positioned in the mold to automatically regulate the width of the joint portion during the crimping process. The predetermined positioning of the regulation portion's wall surfaces ensures that the joint portion width is controlled from the outset, preventing excessive widening while maintaining efficient single-step crimping operation
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 method effectively suppresses deformation of the crimping terminal during the crimping process, facilitating easier accommodation into cavities and reducing the risk of damage to internal components.
Implementation Method 1
a crimp step of deforming the wire connection portion while relatively moving toward the first mold, and crimping the wire connection portion onto the wire by a second mold
Implementation Method 2
a regulation step of regulating a width of the joint portion so as not to be wider than a width of the terminal connection portion, by sandwiching the joint portion from both sides in a width direction when the second mold crimps the wire connection portion by a regulation portion
Data Source
AI summary
A manufacturing method of a crimping terminal includes a terminal supply step of supplying the crimping terminal to a crimping position with a wire by a terminal supply device, the crimping terminal including a terminal connection portion, a wire connection portion to be crimped onto the wire, and a joint portion linking side walls of the terminal connection portion and the wire connection portion, a support step of supporting a bottom portion of the crimping terminal supplied to the crimping position by a first mold, a crimp step of deforming the wire connection portion while relatively moving toward the first mold, and crimping the wire connection portion onto the wire by a second mold, and a regulation step of regulating a width of the joint portion so as not to be wider than a width of the terminal connection portion, by sandwiching the joint portion from both sides in a width direction when the second mold crimps the wire connection portion by a regulation portion.