Crimped Wire Connection with Inclined Sheath for Waterproofing
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Solution Overview
Problem
Existing connection structures between electric wires and terminals face challenges in cost reduction while maintaining water ingress prevention and corrosion suppression, often requiring additional parts like metallic covers.
Innovation Solution
A connection structure featuring an electric wire with an exposed core wire section, a whole circumferential sheath section, and an inclined sheath section, where the terminal is crimped to include crimping pieces that crimp each section, with the inclined sheath section's end surface facing the base plate, allowing the insulating sheath to fill gaps and prevent water ingress without additional covers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic cover is used to cover the conductor, then water ingress prevention is improved, but device complexity and cost increase
Solution Approach 1:
The patent removes the metallic cover from the connection structure, extracting the unnecessary component while maintaining water ingress prevention through the inclined sheath design. The insulating sheath is extended to form an inclined surface that naturally directs water away from the conductor terminal connection, eliminating the need for additional protective covers.
Solution Approach 2:
The inclined sheath section serves dual functions: it provides electrical insulation and acts as a water drainage structure. The inclination angle of 10-45 degrees enables the sheath to self-direct water flow away from the connection point without requiring external protective components, making the structure self-sufficient for both insulation and waterproofing.
2Reliability
If a metallic cover is used to protect the conductor, then corrosion suppression is improved, but cost increases
Solution Approach 1:
The metallic cover is completely removed from the structure. Instead, the insulating sheath material is extended and inclined to provide both insulation and corrosion protection by preventing water contact with the conductor, reducing material quantity while maintaining protective function.
Solution Approach 2:
The patent utilizes the insulating sheath material (typically polymer or plastic) to serve multiple functions including electrical insulation, mechanical protection, and corrosion prevention. By making the sheath inclined, it creates a water-shedding surface that protects the conductor from corrosive water exposure without requiring metallic protective layers.
3Reliability
If the insulating sheath is removed completely to expose the core wire, then electrical connectivity is improved, but water ingress risk increases
Solution Approach 1:
The insulating sheath is selectively positioned: it is removed from the crimping area to ensure good electrical and mechanical connectivity, but extended to form an inclined protective section that covers and protects the exposed conductor end. This local differentiation allows the sheath to provide both connectivity (by being absent where needed) and protection (by being present where water exposure is a risk).
Solution Approach 2:
The sheath extension is given a three-dimensional inclined form rather than a simple linear coverage. The inclination angle creates a sloped surface that actively directs water away from the conductor, adding a functional dimension to the protective coverage that goes beyond simple wrapping or covering.
4Reliability
If the insulating sheath is extended to form an inclined section, then water drainage is improved, but manufacturing precision requirements increase
Solution Approach 1:
Rather than requiring a precise optimal angle, the design accepts a range of inclination angles (10-45 degrees) that all provide effective water drainage. This partial action approach means the sheath is extended beyond the minimum necessary length to ensure that even with manufacturing variations, the inclination remains effective for water shedding without requiring tight tolerances.
Data Source
AI summary
In a connection structure, electric wire includes an inclined sheath section between an exposed core wire section and a whole circumferential sheath section. In the inclined sheath section, an end surface of the insulating sheath on one end side in a longitudinal direction inclines in a direction intersecting the longitudinal direction and thereby a portion of the core wire is exposed. Each of crimping pieces of a terminal has a core wire crimping section that crimps the exposed core wire section, a whole circumferential sheath crimping section that crimps the whole circumferential sheath section, and an inclined sheath crimping section that crimps the inclined sheath section. The terminal is crimped to the electric wire so that the end surface of the inclined sheath section faces a base plate section of the terminal.