Decagon Crimp Die for Composite Core Surface Protection
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Solution Overview
Problem
High voltage transmission conductors with composite cores face challenges in mechanical connection due to the sensitivity of their outer surfaces, which can be damaged by crimping processes, leading to reduced transmission efficiency.
Innovation Solution
A decagon-shaped crimp die with ten planar surfaces positioned at angles forms a crimping area that minimizes deformation and ovalization of the composite core, allowing for secure mechanical connection without damaging the outer surface by distributing radial force evenly across the circumference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional crimp die is used to mechanically secure the composite core to the electrical connector, then the connection strength is improved, but the outer surface of the composite core is damaged leading to reduced transmission efficiency
Solution Approach 1:
The crimp die is segmented into multiple planar surfaces (at least three) that divide the compression force into multiple contact points around the composite core. This segmentation distributes the radial compression force evenly, preventing concentrated stress that would cause surface scratches and cracks, while still achieving sufficient connection strength through the cumulative effect of multiple contact surfaces.
Solution Approach 2:
The crimp die features localized planar surfaces positioned at specific angular intervals around the composite core. Each planar surface provides a localized compression zone that applies force only where needed to secure the connector, while leaving other areas of the composite core surface undisturbed. This localized approach maintains transmission efficiency by avoiding unnecessary surface damage.
2Strength
If radial compression force is applied to secure the composite core, then the mechanical connection is improved, but deformation and ovalization of the composite core occur
Solution Approach 1:
The compression force is segmented into multiple discrete planar surfaces distributed around the composite core circumference. This segmentation prevents concentrated deformation at single points and distributes the shaping effect evenly, maintaining the core's circular cross-section and preventing ovalization while still achieving secure mechanical connection.
Solution Approach 2:
The planar surfaces are arranged in a circular pattern around the composite core, respecting and maintaining the core's naturally circular cross-sectional geometry. This circular arrangement of flat surfaces works in harmony with the curved geometry of the core, applying compression forces that secure the connection without distorting the core's shape or causing deformation.
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
The decagon crimp die effectively secures the composite core to the electrical connector while minimizing damage, ensuring efficient transmission and reducing the risk of fractures, thus enhancing the reliability and performance of high voltage transmission cables.
Implementation Method 1
the crimping area of the inner body includes ten planar surfaces. Each of the ten planar surfaces are positioned at an angle with respect to an adjacent planar surface such that the combination of the ten planar surfaces form a decagon shaped channel... minimizing deformation and ovalization of the composite core, allowing for secure mechanical connection without damaging the outer surface by distributing radial force evenly across the circumference
Data Source
AI summary
A compression die configured to crimp a composite core is disclosed. The compression die includes an outer body having a tool engaging surface, and an inner body coupled to the outer body. The inner body has a crimping area, wherein the crimping area of the inner body includes ten planar surfaces. The ten planar surfaces are positioned at an angle with respect to an adjacent planar surface such that the combination of the ten planar surfaces form a decagon shaped channel. Crimping is performed by the compression die by inserting the composite core into an encasing connector, which is then inserted into the decagon shaped channel of the compression die. A radial force towards the center of the decagon shaped channel is applied until an outer circumference of the encasing connector containing the composite core fully engages a surface area of each of the ten planar surfaces.