Modular Crimp Contact Locking Ring Mechanism
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Solution Overview
Problem
Existing methods for securing electrical connectors to conductors are time-consuming, prone to human error, and not suitable for high-stress applications, lacking modularity and ease of repair.
Innovation Solution
A modular crimp contact system that replaces soldering with a crimping process, using a crimping member, locking ring, and connection member to securely attach a conductor, eliminating unnecessary steps and providing a standardized, reliable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to secure electrical contacts to conductors, then reliable electrical connection is achieved, but assembly time increases and productivity decreases
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical crimping system. The crimping member applies mechanical force to deform and secure the electrical contact to the conductor, eliminating the need for heat, solder material, and lengthy soldering operations while maintaining connection reliability and significantly reducing assembly time.
Solution Approach 2:
The invention changes the fundamental parameter of connection establishment from thermal (soldering temperature and time) to mechanical (crimping force and deformation). This parameter transformation allows the connection to be made quickly through controlled mechanical deformation rather than through a time-consuming thermal process.
2Ease of manufacture
If manual soldering processes are used, then electrical connections can be made, but human error increases and consistency decreases
Solution Approach 1:
The crimping member is designed to automatically perform the connection function through its structural design. The deformation features and geometry of the crimping member guide the assembly process, ensuring consistent deformation and secure attachment without requiring manual dexterity or precise manual control, thereby eliminating human error and improving consistency.
Solution Approach 2:
The connection system is divided into distinct functional components: the crimping member with specific deformation features, the electrical contact, and the conductor. This segmentation allows each component to be optimized for its specific function and ensures that the crimping action is standardized and repeatable, reducing variability in the final connection.
3Reliability
If traditional connector assemblies with multiple components are used, then electrical connections can be established, but device complexity increases and assembly steps increase
Solution Approach 1:
The patent merges multiple traditional connector components into a single integrated crimping member. The crimping member incorporates the functions of securing the electrical contact to the conductor and providing structural support, eliminating the need for separate endbells, collars, and other traditional connector components, thereby reducing overall device complexity while maintaining connection stability.
Solution Approach 2:
The crimping member is designed as a multi-functional component that simultaneously performs mechanical securing, electrical connection, and structural support functions. This universal design replaces multiple specialized components with a single element that accomplishes all necessary functions, simplifying the overall assembly.
4Strength
If soldering and coating processes are used, then durable connections are achieved, but assembly time and process complexity increase
Solution Approach 1:
The patent replaces thermal soldering and coating processes with a purely mechanical crimping system. The crimping member's deformation features create a strong mechanical interlock between the electrical contact and conductor, achieving durable connections without requiring heat treatment, solder application, or protective coatings, thereby eliminating multiple time-consuming process 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 modular crimp contact system significantly reduces assembly time, enhances consistency, and allows for easy repair by eliminating the need for soldering and complex coating processes, while ensuring reliable connections in high-stress environments.
Implementation Method 1
the crimping body end having a crimping body cavity adapted to receive the conductor, wherein the conductor is secured within the crimping body cavity by being crimped by the crimping body end of the crimping member
Implementation Method 2
The locking ring, when seated in the locking ring recess, may secure the contact end of the crimping member within the receiving end cavity
Data Source
AI summary
The present invention relates to a modular crimp contact system and method. The modular crimp contact system comprises a crimping member secured to a conductor by having one end of the crimping member crimped about the exterior of the conductor. A locking ring disposed about the body of the crimping member locks the crimping member in a receiving end of a connection member. The connection member may have a pin or a socket on a connection end opposite the receiving end the connection member.