Elastic Terminal Connection for Fine Wire Integrity
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Solution Overview
Problem
Existing connection structures for electric-wires and terminals often break extra-fine core wires and are limited by crimping die dimensions, making it difficult to connect narrow pitch connectors securely.
Innovation Solution
A connection structure featuring a terminal with an elastic connection piece formed by folding a base plate, including first and second elastic connection parts with wire insertion holes, allowing the core wire to be inserted and sandwiched without breaking, and enabling connection without crimping die limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tip end of the wire barrel is crimped to stick into the core wire by a crimping mold, then the connection between the wire barrel and core wire is improved, but the core wire may be broken when strands are extra-fine
Solution Approach 1:
The patent introduces an elastic connection piece as an intermediary component between the wire barrel and the core wire. This elastic connection piece deforms elastically during the crimping process to accommodate the core wire without causing damage, while still providing sufficient connection strength. The elastic material acts as a buffer that mediates the force between the rigid wire barrel and the fragile core wire strands.
Solution Approach 2:
The patent changes the physical state and mechanical properties of the connection structure by using an elastic connection piece that can deform. The elastic connection piece transitions from a loose state to a compressed state during crimping, changing its density and rigidity to provide gradual compression force on the core wire rather than sudden impact, thereby preventing wire breakage while maintaining connection strength.
2Ease of manufacture
If a crimping mold is used to connect the wire barrel to the core wire, then the connection process is simplified, but the size of the connection structure is limited by the dimensions of the crimping die
Solution Approach 1:
The patent employs an elastic connection piece that can dynamically adapt its shape and size during the connection process. The elastic material can be compressed to fit into narrow spaces and then expands to provide connection force, allowing the same connection structure to work with various connector pitches without requiring different sized crimping dies.
Solution Approach 2:
The elastic connection piece functions as a flexible component that can be compressed and deformed to fit into tight spaces characteristic of narrow pitch connectors. This flexible element can be inserted through small openings and then expanded to engage the core wire, providing a universal solution that is not constrained by the dimensions of rigid crimping dies.
3Manufacturing precision
If the core wire is crimped with extra-fine strands, then the connection precision is improved, but the core wire may be broken by the tip end of the wire barrel
Solution Approach 1:
The elastic connection piece serves as a cushioning element that is already in place before the crimping force is applied. It provides a soft, compliant interface between the wire barrel and the extra-fine core wire strands, absorbing and distributing the crimping force to prevent localized stress concentrations that would cause wire breakage while maintaining precise alignment.
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 solution securely connects electric-wires to terminals without breaking the core wire and accommodates narrow pitch connectors, reducing the risk of wire damage and expanding compatibility beyond conventional crimping die constraints.
Implementation Method 1
pressing the first elastic connection part and the second elastic connection part in a direction reducing the inclination of both the first elastic connection part and the second elastic connection part with respect to the base plate
Data Source
AI summary
A connection structure of an electric wire and a terminal includes a terminal formed by folding back a base plate to form a body part and an elastic connection piece, and an electric wire having a core wire exposed from an insulation sheath. The elastic connection piece includes a first elastic connection part adjacent to a folded-back portion of the base plate and a second elastic connection part continuing to the first elastic connection part in the longitudinal direction of the base plate. An electric wire insertion hole is formed on each of the elastic connection parts. The core wire is sandwiched and connected by the elastic connection piece and the body part at a position between the first elastic connection part and the second elastic connection part at a state where the core wire is inserted through the wire insertion holes in the longitudinal direction of the base plate.