Flat Circuit Body Terminal Crimping for Connection Strength
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Solution Overview
Problem
Conventional flat circuit bodies with terminals face challenges in improving mechanical and electrical connection performance due to uneven contact area between flat conductors and terminals, and variations in crimping strength and performance.
Innovation Solution
A flat circuit body design with crimp claws raised at opposed positions on the terminal's bottom plate, allowing for equal crimp force application and increased contact area, along with serrations on the bottom plate and crimp claws to enhance connection strength and stability, and prescribed crimping structure to maintain consistent performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If crimp claws are arranged in a zigzag form to shift from each other in position, then the terminal structure is simplified, but the contact area between flat conductor and terminal is reduced and connection performance deteriorates
Solution Approach 1:
The patent applies asymmetry by positioning crimp claws at opposed locations on the bottom plate rather than in a zigzag pattern. This symmetric opposed positioning ensures that both crimp claws contact the flat conductor simultaneously and uniformly, maximizing the contact area while maintaining structural simplicity. The asymmetric alternative (zigzag arrangement) was rejected because it reduces contact area and connection reliability.
2Reliability
If crimp claws are raised at opposed positions on the bottom plate, then contact area and electrical connection performance are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-forming the bottom plate with raised portions at opposed positions before the crimping process. These raised portions are precisely positioned and formed in advance, ensuring that crimp claws are automatically positioned correctly when mounted on the terminal. This preliminary structuring of the bottom plate eliminates the need for high-precision positioning during assembly, as the raised portions guide the crimp claws into the correct positions.
3Ease of manufacture
If conventional crimping is used without prescribed structure, then manufacturing process is simpler, but mechanical connection strength varies and reliability decreases
Solution Approach 1:
The patent applies parameter changes by prescribing specific geometric parameters for the crimp claws and their relationship to the bottom plate raised portions. The crimp claws are designed with specific dimensions, angles, and positions that are optimized to engage with the flat conductor in a controlled manner. These parameter specifications ensure consistent crimping force distribution and contact pressure, resulting in reliable mechanical connection strength while maintaining ease of manufacture through standardized designs.
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 design secures high connection strength and improves electrical connection performance by increasing contact area, while minimizing variations in mechanical and electrical connection strength through controlled crimping, facilitating easier terminal mounting and stable contact resistance.
Implementation Method 1
the top layer is configured to be plastically deformed so as to fill a gap between the top layer and inner surfaces of the crimp claws when the crimp claws are crimped onto the top layer
Data Source
AI summary
A portion of a flat conductor is exposed from an insulating layer covering at least one of surfaces of the flat conductor. A terminal includes a bottom plate on which the exposed portion of the flat conductor is provided, and crimp claws which are raised at two side edges of the bottom plate so that the exposed portion is disposed therebetween. The exposed portion is folded so as to define a bottom layer which faces the bottom plate and a top layer which faces opposite to the bottom plate. The top layer is configured to be plastically deformed so as to fill a gap between the top layer and inner surfaces of the crimp claws when the crimp claws are crimped onto the top layer, so that the bottom layer is in surface contact with the bottom plate.