Power Terminal Crimping Tabs for Aluminum Cable Sealing
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Solution Overview
Problem
Existing solutions for making intermediate connections on aluminum electric power cables are complex and fail to provide adequate sealing, as aluminum conductors corrode easily when exposed to external agents, necessitating a simpler and more effective sealing method.
Innovation Solution
A terminal with a conducting metal body featuring crimping tabs at each end, which deform the insulating sleeve of the cable for a secure and watertight seal, allowing for easy connection and sealing of aluminum cables by welding the cable to the terminal and clamping the tabs around the sleeve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal is clamped to an aluminum cable at an intermediate point, then an intermediate connection is achieved, but adequate sealing is difficult to obtain and the process becomes complex
Solution Approach 1:
The patent combines the clamping function and sealing function into a single integrated terminal structure. The crimping tabs simultaneously clamp the cable conductor and seal the insulating sleeve, eliminating the need for separate sealing operations and simplifying the overall connection process while ensuring reliable sealing against corrosion
Solution Approach 2:
The terminal is designed with pre-formed crimping tabs that are positioned and shaped in advance to perform both clamping and sealing functions in a single operation. The tabs are pre-configured with sealing surfaces that will contact and seal the insulating sleeve when the crimping operation is performed, ensuring sealing is achieved before any potential corrosion exposure
2Weight of moving object
If aluminum conductors are used, then weight is reduced, but corrosion resistance deteriorates when exposed to external agents
Solution Approach 1:
The patent converts the vulnerability of aluminum conductors to corrosion into a benefit by designing the crimping tabs to create a sealed environment around the insulating sleeve. The sealing action traps the aluminum conductor inside, protecting it from external corrosive agents while maintaining the weight advantage of aluminum. The very act of crimping that secures the electrical connection also creates the protective seal
Solution Approach 2:
The patent uses the insulating sleeve as a flexible shell that is deformed by the crimping tabs to create a seal. The sleeve material is chosen to be sufficiently flexible to allow deformation during crimping while maintaining its integrity to provide corrosion protection. The deformed sleeve acts as a barrier film between the aluminum conductor and external environment
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 provides a simple and effective method for forming intermediate connections on aluminum cables, ensuring a completely watertight seal through the deformation of the insulation by the crimping tabs, which can be further sealed with heat-shrinkable material or co-molding, addressing the corrosion issues of aluminum conductors.
Implementation Method 1
a support part configured to receive an intermediate portion of the electric cable welded to the support part
Implementation Method 2
a pair of crimping tabs extending from the transversally opposite sides of the support part and capable of being clamped by deformation around an insulating sleeve
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A terminal (10) for intermediate connection to an electric cable (20), comprising a body of conducting metal material having a connection part (11) configured to be connected to a user device, and a support part (13) configured to receive an intermediate portion (21) of the electric cable (20) welded to the support part (13). The terminal comprises, on each of longitudinally opposite ends of the support part (13), a pair of crimping tabs (15a, 15b; 16a, 16b) extending from transversely opposite sides of the support part (13) and susceptible to be clamped by deformation around an insulating sleeve (23) of the electric cable (20) adjacent to the intermediate portion (21) of the electric cable (20), wherein each pair of tabs (15a, 15b; 16a, 16b) comprises at least one rib (17, 18) adapted to engage the insulating sleeve (23) of the electric cable (20) and extending transversely between the opposite free ends (15a', 15b'; 16a', 16b') of the pair of tabs (15a, 15b; 16a, 16b').