Crimping Terminal Wire Hook for Pull-Out Resistance
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Solution Overview
Problem
Conventional crimped electrical terminals in vehicles face issues with wire pull-out due to increasing weight and force from numerous electrical connections, leading to a need for enhanced connection strength.
Innovation Solution
The electrical terminal design includes a wire hook between side walls, with crimp tabs and tongues that engage the insulator and conductor, respectively, and a crimped position that secures the wire with increased resistance to pull-out force by bending the wire hook to engage the conductor's bend.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional crimped electrical terminals are used with increasing wire harness weight, then the number of electrical connections increases, but the wire pull-out force increases leading to reduced connection reliability
Solution Approach 1:
The terminal is divided into multiple functional components: crimp tabs for insulator engagement, crimp tongues for conductor engagement, and wire hooks for additional mechanical anchoring. This segmentation allows each component to contribute to resistance against pull-out forces independently, significantly improving overall connection reliability under increased wire harness weight
Solution Approach 2:
The wire hooks extend laterally between the side walls, adding a dimensional element perpendicular to the traditional crimp direction. This creates multiple engagement points (crimp tabs on insulator, crimp tongues on conductor, and wire hooks on conductor bend) that collectively resist pull-out forces from multiple directions and mechanisms
2Strength
If the wire harness weight increases due to more electrical connections, then the mechanical connection strength must increase, but the conventional crimp structure becomes insufficient
Solution Approach 1:
The invention merges multiple connection mechanisms into a single integrated terminal structure: the crimp tabs engage the insulator, the crimp tongues engage the conductor, and the wire hooks engage the conductor bend. This combination of mechanical engagement methods within one terminal component significantly increases the overall mechanical connection strength required to support increased wire harness weight
Solution Approach 2:
The wire hooks are pre-formed as integral parts of the terminal before assembly. During the crimping process, the conductor is positioned so that its bend engages the wire hooks before final crimping occurs. This preliminary positioning ensures that the mechanical connection is established in advance to withstand the increased forces from heavier wire harnesses
Data Source
AI summary
An electrical terminal includes a conductor barrel and a contact portion that is adapted to mate with a corresponding terminal. A terminal base extends from the conductor barrel to the contact portion. The electrical terminal includes a first side wall and a second side wall that extend from the contact base between the conductor barrel and the contact portion. A wire hook extends between the first side wall and the second side wall. A first wire space is defined between the wire hook and the first side wall and a second wire space is defined between the wire hook and the second side wall.