Insulative Resin Strain Relief for Crimped Wire Connections
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Solution Overview
Problem
Traditional waterproof crimping structures require complex operations and high manufacturing costs due to the need for bending wires into specific shapes and using intricate metal dies for strain relief, which increases the overall cost and complexity.
Innovation Solution
A crimping structure where the coated electric wire is bent into a mountain-like shape and crimped onto a crimping blade part, with an insulative resin part covering it, allowing the resin to absorb external forces and provide strain relief without applying pressure on the connecting part, and the crimping blade part is protruded from the base plate for easier resin molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional waterproof crimping structures use complex operations to bend wires into specific shapes and use intricate metal dies for strain relief, then strain relief function is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines the strain relief function with the insulative resin part by integrating the strain relief structure directly into the resin molding. The insulative resin part includes a strain relief structure that accommodates the coated electric wire, eliminating the need for separate metal dies and complex bending operations. This merging of functions reduces manufacturing steps and costs while maintaining effective strain relief.
Solution Approach 2:
The insulative resin part serves as an intermediary that provides strain relief through its integrated structure. Instead of using complex metal dies, the resin part itself forms the strain relief mechanism through its molded geometry, which accommodates and protects the wire connection point without requiring additional components or complex manufacturing steps.
2Reliability
If complex metal dies are used for strain relief in traditional structures, then strain relief is achieved, but device complexity increases
Solution Approach 1:
The strain relief function is merged into the insulative resin part itself. The resin part includes an integrated strain relief structure that eliminates the need for separate metal dies and complex mechanical components. This single-integration approach simplifies the overall device structure while maintaining effective strain relief functionality.
Solution Approach 2:
The patent extracts the strain relief function from complex metal dies and reimplements it through the geometric design of the insulative resin part. By taking out the need for intricate metal components and replacing them with a simplified resin-based structure, the overall device complexity is reduced while preserving the strain relief capability.
3Reliability
If separate operations are used for crimping and strain relief, then each function is achieved, but productivity decreases
Solution Approach 1:
The patent merges the crimping and strain relief operations into a single integrated process. The insulative resin part is molded to include both the crimping structure and the strain relief structure, allowing both functions to be achieved in one manufacturing step rather than through separate operations. This significantly improves manufacturing efficiency and productivity.
Solution Approach 2:
The strain relief structure is preliminarily formed as part of the insulative resin part during the molding process. By pre-integrating the strain relief geometry into the resin part before the crimping operation, the subsequent crimping process can proceed without additional strain relief steps, thereby improving overall manufacturing efficiency.
4Reliability
If the insulative resin part covers the connecting part, then waterproofing is improved, but inspection difficulty increases
Solution Approach 1:
The insulative resin part is segmented to include both a covering portion for waterproofing and an exposing portion for inspection. The resin part is configured to cover the connection between the conductor and crimping blade for waterproofing, while simultaneously exposing the hem parts of the coated electric wire to allow visual inspection of the crimping quality without compromising the waterproof seal.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A crimping structure includes a crimping terminal that has a base plate and a crimping blade part on the base plate, a coated electric wire that has a conductor which is electrically connected to the crimping blade part by crimping the coated electric wire to the crimping blade, and is bend to be formed into a mountain-like shape whose top part is a connecting part where the conductor and the crimping blade part are connected, and an insulative resin part that covers a part of the coated electric wire from the top part to hem parts at two sides of the mountain-like shape and the crimping blade part.