Insulation Barrel Crimp Layout for Higher Wire Terminal Holding Force
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Solution Overview
Problem
Existing wire terminal configurations experience a reduction in holding force due to improper alignment of insulation barrel pieces, leading to reduced retention of the wire.
Innovation Solution
The wire terminal design includes a wire barrel and insulation barrel with specific extending pieces that lock onto the coating, ensuring the insulation barrel pieces are positioned closer to the center, preventing movement and maintaining a strong hold even when wound, and the insulation barrel pieces are curved to face each other, providing uniform pressure on the shield conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the one-side extending portion of the wire barrel is wound on the exposed conductor, then the wire barrel is secured to the conductor, but the one-side insulation barrel piece is pulled toward the other side causing misalignment and reduced holding force
Solution Approach 1:
The insulation barrel is divided into two separate extending portions (one-side and other-side insulation barrel pieces) that can be independently positioned and crimped. This segmentation allows each piece to be optimally aligned with the coating without interference from the other, preventing the pulling effect that causes misalignment while maintaining secure holding force.
Solution Approach 2:
The one-side and other-side insulation barrel pieces are positioned at different locations along the coating - the one-side piece covers one side of the coating while the other-side piece covers the other side. This local differentiation allows each piece to be crimped independently at its optimal position, ensuring precise alignment and maximum holding force without mutual interference.
2Reliability
If the insulation barrel pieces are crimped to press toward the inside of the wire, then connection security is improved, but the other-side insulation barrel piece butts against the one-side piece without being pushed in, reducing holding force
Solution Approach 1:
By segmenting the insulation barrel into two separate extending portions, each piece can be crimped independently to press toward the inside of the wire without being blocked by the other piece. This eliminates the blocking effect that reduces holding force while maintaining connection security through dual-piece crimping.
Solution Approach 2:
The insulation barrel pieces extend from opposite sides (width direction) toward the center, utilizing lateral positioning to avoid interference. This dimensional arrangement allows both pieces to achieve proper crimping depth and holding force simultaneously, as they approach from different spatial dimensions rather than blocking each other in a single line.
Data Source
AI summary
A terminal includes a wire barrel and an insulation barrel. The wire barrel includes a wire barrel base portion, a one-side wire barrel piece and an other-side wire barrel piece to be laid on an outer periphery of the one-side wire barrel piece. The insulation barrel includes an insulation barrel base portion connected to and behind the wire barrel base portion, a one-side insulation barrel piece for covering one side of an outer periphery of a coating and an other-side insulation barrel piece for covering the other side of the outer periphery of the coating. Tips of the respective one-side and other-side insulation barrel pieces are locked to the coating of a wire on a side closer to the other side than a center in a width direction of the insulation barrel.