Terminal-Equipped Wire Polygonal Barrel Crimping
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Solution Overview
Problem
Conventional terminal-equipped wires face issues with fixing strength and manufacturing cost due to the need for complex processing and increased parts, especially when subjected to tensile loads orthogonal to the axial direction, leading to potential opening of barrel pieces.
Innovation Solution
A terminal-equipped wire configuration where the barrel pieces are crimped into a polygonal tube shape around the external sheath with leading end edges arranged on opposite sides of corner portions, providing strong crimping and resistance to external forces, and optionally incorporating a shield layer and uneven abutting edges to enhance fixing strength and workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the barrel pieces are crimped into a curved cross-sectional shape around the wire, then the wire can be simply wrapped around the end of the wire, but the fixing strength is insufficient when subjected to tensile loads in a direction orthogonal to the axial direction
Solution Approach 1:
The invention inverts the conventional curved cross-sectional shape into a polygonal cross-sectional shape with corner portions. The leading end edges of the barrel pieces are positioned on opposite sides of at least one corner portion, creating mechanical interlocking that prevents opening under orthogonal tensile loads while maintaining simple wrapping installation
Solution Approach 2:
The polygonal cross-sectional shape introduces asymmetry with corner portions that break the rotational symmetry of conventional curved barrels. This asymmetry creates specific engagement points (corner portions) that provide directional resistance to opening forces, enhancing fixing strength without complicating the wrapping process
2Strength
If an annular sleeve is added and the barrel pieces are crimped onto a braided member having the sleeve as an underlayer, or the barrel is formed as a closed barrel, then the fixing strength of the crimping portion is improved, but processing such as cutting and welding needs to be performed on parts, leading to an increase in costs
Solution Approach 1:
The invention extracts and eliminates the annular sleeve component from the conventional structure. By forming the barrel pieces with a polygonal cross-sectional shape directly, the patent achieves enhanced fixing strength through the corner portion mechanism without requiring the additional sleeve part, thereby reducing part count and eliminating cutting and welding operations
Solution Approach 2:
The invention merges the function of the annular sleeve into the barrel piece structure itself. The polygonal cross-sectional shape with corner portions integrates the mechanical interlocking function that previously required a separate sleeve component, simplifying the overall structure while maintaining or enhancing fixing strength
Data Source
AI summary
A terminal-equipped wire configured by crimping a pair of barrel pieces provided on a terminal to an external sheath of a wire, the external sheath being provided on an outer circumferential surface of a core wire. The pair of barrel pieces are wrapped around the external sheath into a polygonal tube shape that has a plurality of corner portions in a circumferential direction of the external sheath, leading end edges of the pair of barrel pieces are arranged on opposite sides of at least one corner portion out of the plurality of corner portions.