Flat Wire Tip Structure for Crimp Terminals
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Solution Overview
Problem
Connecting flat wires to crimp terminals is challenging due to their larger lateral width, requiring multiple steps and increasing labor and cost, and can result in reduced tensile strength when thin wires are punched to fit, leading to asymmetric connections and load distribution.
Innovation Solution
A tip structure for flat wires featuring a slit formed along the length, dividing the tip into overlapping strips that are vertically and laterally pressed to reduce width, allowing easy insertion into crimp terminals while maintaining tensile strength through increased thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If punching is performed to reduce lateral width of the tip, then the tip can be inserted into the crimp terminal, but the tensile strength is reduced
Solution Approach 1:
The invention transitions from reducing width in the horizontal dimension to reducing width by folding in the vertical dimension. The tip is folded back along its length direction, creating an overlapping structure that reduces the lateral width while preserving the full cross-sectional area and tensile strength of the original wire.
Solution Approach 2:
The tip structure is divided into multiple overlapping sections through folding. The tip portion is folded back to create multiple layers that overlap, effectively segmenting the original continuous structure into stacked segments that achieve width reduction without compromising strength.
2Ease of operation
If V-shaped bending or round bending is performed to reduce lateral width, then the tip can be inserted into the crimp terminal, but the number of steps increases
Solution Approach 1:
The invention combines the width reduction function and the insertion function into a single folding operation. Instead of performing separate bending operations (V-shaped or round bending) followed by insertion, the tip is folded back once to simultaneously achieve the reduced width configuration and prepare for direct insertion into the crimp terminal.
3Ease of operation
If punching is performed to reduce lateral width, then the tip can be inserted into the crimp terminal, but the connection becomes asymmetric
Solution Approach 1:
The invention intentionally creates a symmetric folded structure where the tip is folded back onto itself, creating equal overlapping layers on both sides of the fold. This symmetric folding configuration ensures uniform load distribution and symmetric connection characteristics, contrasting with the asymmetric result of punching operations.
Data Source
Figure 1A~1C
Figure 2
Figure 3
AI summary
A slit 21 having a predetermined width and a predetermined length is formed in a longitudinal direction from a middle of a distal edge of a tip 20 of a flat wire 10 (Figure 1A). Next, one of a left strip 22a and a right strip 22b is brought upward and the other is brought downward, and then the left strip 22a and the right strip 22b vertically separated are laterally brought close to each other (Figure 1B). Finally, the left strip 22a and the right strip 22b are vertically pressed to abut against each other (Figure 1C) .