Sealed Electrical Connector Crimping Copper and Aluminum Conductors
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Solution Overview
Problem
Existing electrical connection methods for motor vehicles, such as crimping and ultrasonic welding, face challenges in providing a reliable and cost-effective sealed connection for both copper and aluminum conductors, particularly in aggressive environments and complex harness configurations.
Innovation Solution
A sealed electrical connection member comprising a continuous tube with a deformed section and annular ends, allowing crimping of conductors and terminals, which ensures airtight and watertight connections without the need for additional sealing elements, suitable for both copper and aluminum conductors, and can be standardized based on conductor diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If open-barrel copper alloy terminals are used for crimping copper conductors, then electrical conductivity is maintained, but aluminum conductors cannot be connected due to lower electrical conductivity and susceptibility to electrolysis
Solution Approach 1:
The terminal is divided into two distinct sections: a first section for crimping copper conductors and a second section for crimping aluminum conductors. Each section has optimized geometry and material properties suited to its specific conductor type, allowing the terminal to handle both materials reliably without compromise.
Solution Approach 2:
The terminal uses composite construction with a copper alloy body and an aluminum-compatible section (either aluminum alloy or copper alloy with aluminum oxide layer). This composite structure enables the terminal to provide good electrical conductivity for copper connections while preventing electrolysis when connecting aluminum conductors.
2Shape
If tubular lugs are used to connect copper conductors, then connection simplicity is maintained, but complex shapes cannot be achieved which are needed to optimize space requirements
Solution Approach 1:
The terminal is segmented into functional zones: a crimping section for conductor attachment and a deformation section that can be shaped into complex configurations. This segmentation allows the terminal to achieve complex spatial arrangements while maintaining simple crimping operations.
Solution Approach 2:
The terminal includes a deformation section that can be locally deformed into various shapes (U-shaped, V-shaped, etc.) to optimize space requirements. This dynamic shaping capability allows the same basic terminal structure to adapt to different spatial constraints in the wiring harness.
3Shape
If ultrasonic welding is used to connect aluminum conductors to lugs with complex shapes, then complex shapes can be achieved, but manufacturing cost increases and sealing problems arise in harsh environments
Solution Approach 1:
The patent replaces ultrasonic welding (a complex mechanical/thermal process) with a pure crimping operation. The terminal's deformation section is designed to be crimped onto the conductor, creating both the complex shape and the electrical connection in a single simple mechanical operation that is cost-effective and provides reliable sealing.
4Reliability
If additional sealing elements are added to ensure watertight connections, then sealing reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The sealing function is merged with the structural function of the terminal itself. The deformation section of the terminal creates both the mechanical connection and the sealing barrier in one integrated component, eliminating the need for separate sealing elements like gaskets or sealants.
Solution Approach 2:
The terminal's deformation section is designed to self-seal when crimped. The geometry of the deformation creates inherent sealing surfaces that prevent water and air infiltration without requiring additional sealing materials or operations. The terminal serves its own sealing needs through its own structural deformation.
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, cost-effective, and reliable method for connecting electrical wiring elements, ensuring a high compaction rate for tightness and mechanical integrity, while avoiding the expense and complexity of ultrasonic welding, and maintaining electrical conductivity and resistance to oxidation.
Implementation Method 1
crimp an electrical conductor into the annular end of the tube
Implementation Method 2
crimp an open-end lug onto the deformed section of the tube... allows for a high-compression crimp, which guarantees a watertight connection
Implementation Method 3
the bonding surface of the strip's ends would create both an area where air or water could infiltrate
Data Source
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Figure 9
AI summary
This electrical cable comprises: - an electrical wiring element, and - an electrical connection element (2) crimped to the electrical wiring element in a hermetic manner and capable of connecting the electrical wiring element to another electrical wiring element. The element (2) comprises a tube (4) having at least one annular end (8) providing access to an internal housing of the tube (4), and at least one section (10) in which a cross-section of the tube (4) is deformed so that it comprises several portions joined to one another or to each other.