Multi-zone Mold Crimping for Electrical Connectors
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Solution Overview
Problem
The existing crimping methods for electrical connectors are time-consuming, tedious, and lack reproducibility, requiring multiple operations to achieve effective electrical and mechanical connections.
Innovation Solution
A crimping method using a mold with varying wall shapes to perform two crimps in one operation, incorporating ridges on the second connector for pressure points to improve tensile strength and electrical conductivity, allowing for adjustable electrical and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple crimping operations are performed to achieve proper electrical and mechanical connection, then the connection quality is improved, but the production time and process complexity increase
Solution Approach 1:
The patent combines multiple crimping operations into a single mold with multiple cavities. Each cavity performs a different crimping function (electrical connection, mechanical bonding, aesthetic finishing) simultaneously during one pressing operation, thereby maintaining connection quality while dramatically reducing production time and process complexity
Solution Approach 2:
The mold is designed as a multi-functional tool that performs multiple crimping functions in one operation. Different zones of the mold apply different pressures and deformations to achieve electrical connection, mechanical bonding, and aesthetic finishing simultaneously, making the mold a universal device for complete connector assembly
2Reliability
If multiple crimping operations are performed to ensure proper connection, then the connection reliability is improved, but the process reproducibility decreases
Solution Approach 1:
By merging all crimping operations into a single mold closure action, the patent eliminates variations between separate operations. The fixed relative positions of mold cavities ensure that electrical, mechanical, and aesthetic crimps are applied simultaneously with consistent positioning, greatly improving process reproducibility while maintaining connection reliability
3Productivity
If the mold walls have varying shapes in different zones to perform different crimps, then the crimping process is simplified, but the mold design complexity increases
Solution Approach 1:
The mold is segmented into multiple zones or cavities, each with specifically shaped walls designed for different crimping functions. This segmentation allows each zone to perform a specific task (electrical connection, mechanical bonding, aesthetic finishing) while the overall mold structure remains relatively simple and modular, balancing design complexity with process simplification
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
Simplifies the crimping process, enhances reproducibility, and improves both mechanical and electrical properties by creating multiple pressure points that break the alumina layer on aluminum connectors, increasing contact surface and tensile strength.
Implementation Method 1
pressing a section of this assembly together, where the second connector covers the first. This compression, which must be sufficient to deform the section, ensures electrical contact between the two connectors
Implementation Method 2
the ridges on the second connector create multiple pressure points on the first connector, allowing the second connector to grip the first. This improves the tensile strength of the assembly, thereby enhancing the mechanical properties of the crimp. This is even more advantageous if the first electrical connector is made of aluminum. The pressure points created by the second connector allow the insulating layer of alumina, which forms on the surface of the first connector through oxidation, to break down.
Data Source
Figure 1~3
Figure 4~6b
AI summary
In a crimping process of a first connector (4) into a second connector (6), the two connectors (4, 6) are pressed between first and second walls of a mold (21), these walls each having different shapes in areas following one another along a main axis (8) of the connectors (4, 6).