Integral Terminal with Oxide Breaker for Aluminum Wire
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Solution Overview
Problem
Existing electrical connectors for aluminum wires face challenges in achieving efficient electrical conductivity due to the oxide layer, require multiple pieces leading to increased costs and assembly errors, and often result in strand severance and non-linear alignment, while also failing to create a consistent and moisture-resistant connection.
Innovation Solution
An integral electrical terminal with a continuous annular interior wall featuring a crimp portion that includes a contact portion with an integral oxide breaker comprising tapered protrusions coated with nickel, and a sealing portion with integral seal rings, designed to break through the oxide layer and provide a secure, airtight connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical crimping is used to attach terminal to aluminum wire, then connection speed is improved, but electrical conductivity deteriorates due to oxide layer
Solution Approach 1:
The patent applies preliminary action by incorporating an oxide breaker component that removes the oxide layer from the aluminum wire before the crimping process occurs. The oxide breaker is positioned to contact and scrape away the oxide layer during wire insertion, preparing the surface for subsequent mechanical crimping. This preliminary removal of the oxide barrier enables both fast mechanical connection and good electrical conductivity to be achieved together.
2Ease of manufacture
If multiple pieces are used in terminal construction, then ease of manufacture is improved, but device complexity increases leading to assembly errors
Solution Approach 1:
The patent applies the merging principle by integrating multiple previously separate components into a single integral terminal structure. The terminal combines the connector portion, wire barrel, oxide breaker, and sealing elements into one unified piece that is formed as a single component. This eliminates the need for assembling multiple separate parts, reducing assembly complexity and potential for errors while maintaining manufacturing feasibility through integral forming processes.
3Strength
If extensive crimping is applied to secure terminal, then mechanical strength is improved, but geometry consistency deteriorates due to deformation
Solution Approach 1:
The patent applies segmentation by dividing the terminal into distinct functional zones: a connector portion for mounting, a wire barrel for wire reception, and a crimp portion for mechanical securing. The crimp portion is specifically designed with geometry that accommodates deformation during crimping while maintaining overall alignment. This segmented approach allows localized deformation in the crimp zone without compromising the geometric precision of the connector portion and mounting surfaces.
4Ease of manufacture
If conventional terminal design is used, then ease of manufacture is improved, but reliability deteriorates due to strand severance and moisture infiltration
Solution Approach 1:
The patent combines protective functions into the integral terminal structure by incorporating sealing portions that prevent moisture infiltration and designing the wire barrel to protect strands from severance during crimping. The single-piece construction inherently protects wire strands by providing a continuous protective barrier, while integrated sealing elements block moisture paths without requiring separate assembly steps.
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 solution ensures efficient electrical conductivity, reduces assembly complexity and costs, minimizes strand severance, and maintains consistent geometry and moisture resistance, as demonstrated by successful testing under thermal shock, current cycling, and hydrostatic seal conditions.
Implementation Method 1
the chemistry of aluminum oxidation makes crimping to an aluminum wire more difficult than to a copper wire
Implementation Method 2
an integral oxide breaker comprising a plurality of tapered protrusions extending inwardly in the contact portion, the tapered protrusions having a coating thereon
Implementation Method 3
Mechanical crimping of a terminal around a wire is commonly used
Implementation Method 4
Another consideration in cable manufacture is how to create a cable that resists moisture and air infiltration between the terminal and the conductor
Data Source
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AI summary
A one piece integral electrical terminal has a mount portion and a wire receiving portion. The wire receiving portion has a continuous annular interior wall having a contact portion with an integral oxide breaker especially suited to breaking through the oxide layer on aluminum wire. The wire receiving portion also has a sealing portion with at least one integral seal ring. An electrical cable is made by crimping the electrical terminal to an aluminum wire using a modified hexagonal crimp.