Insulated Wire Terminal Connection Structure with Depth Indicator
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Solution Overview
Problem
Existing wire-terminal connection structures lack a reliable method to visually confirm the proper insertion depth of a conductor into a crimp terminal, leading to potential improper pressure-bonding and reduced conductive and water-blocking performance.
Innovation Solution
An insulated wire-terminal connection structure featuring a sign on the outer circumferential face of the insulating cover, made of a more flexible material than the cover, indicating the insertion length of the wire tip into the pressure-bonding section, ensuring the conductor is inserted to a predetermined position for optimal pressure-bonding and water-blocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the insertion hole of the pressure-bonding section is made small and closed at the front end, then the pressure-bonding strength is improved, but the ability to visually confirm proper insertion depth is worsened
Solution Approach 1:
A sign made of flexible material is introduced as an intermediary element on the insulating cover to indicate insertion depth. This sign serves as a mediator between the closed pressure-bonding section and the operator, allowing visual confirmation without opening the section or compromising its sealing function.
Solution Approach 2:
The sign utilizes color or visual contrast changes to indicate proper insertion depth. The flexible sign can be positioned to show different visual states (e.g., color-coded zones, visible/hidden portions) that correspond to correct insertion depth, enabling easy visual detection.
2Device complexity
If no insertion depth indicator is provided, then the device complexity is reduced, but the manufacturing precision of wire insertion is worsened
Solution Approach 1:
The insulating cover itself provides the indication function through the flexible sign attached to it. The sign leverages the existing structure of the insulating cover, eliminating the need for separate indicator mechanisms or complex positioning systems, thus maintaining simple device structure while achieving precise insertion control.
Solution Approach 2:
The flexible material of the sign changes its physical state (position, shape, or visibility) in response to insertion depth. This parameter change provides visual feedback about insertion precision without requiring complex measurement systems.
3Ease of operation
If the wire tip is insufficiently inserted into the pressure-bonding section, then the ease of operation is improved, but the reliability of electrical connection is worsened
Solution Approach 1:
The flexible sign provides immediate visual feedback about insertion depth. As the wire is inserted, the sign's position or appearance changes to indicate whether the correct depth has been reached, allowing operators to achieve reliable connections without excessive force or complex procedures.
Data Source
AI summary
In a terminal connection method of inserting a wire tip of an insulated wire, which is formed by stripping a front end of an insulating cover to expose an aluminum core wire, into a pressure-bonding section of a female crimp terminal to pressure bond the insulated wire to the female crimp terminal via the pressure-bonding section, signs are formed on the outer circumferential face of an insulated tip of the insulating cover at a distance of an internal length of the pressure-bonding section from a conductor tip face of the conductor tip, and the wire tip is inserted up to the signs in the pressure-bonding section to pressure-bond the wire tip to the pressure-bonding section.