Segmented Crimp Terminal Design for Stable Conductivity
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Solution Overview
Problem
Existing crimp terminals struggle to achieve stable conductivity and water-blocking performance due to air gaps and deformation issues when connecting insulated wires, particularly with dissimilar metal corrosion risks.
Innovation Solution
A crimp terminal design featuring a pressure-bonding section with a cover pressure-bonding section and a conductor pressure-bonding section of different diameters, integrated via a diameter reduction portion, ensuring secure contact and preventing air gaps, along with a weak pressure-bonding section for enhanced water-blocking and corrosion prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the conductor tip portion is inserted to the caulking portion together with the conductor tip, then the insulating cover can be secured, but the caulking portion cannot be closely contacted firmly with the conductor tip and air gaps are generated
Solution Approach 1:
The pressure-bonding section is divided into two distinct sections: a cover pressure-bonding section for receiving the insulating cover and a conductor pressure-bonding section for receiving the conductor tip. This segmentation allows each section to be optimized for its specific function, eliminating air gaps while maintaining water-blocking performance.
Solution Approach 2:
The conductor pressure-bonding section is designed with a smaller diameter than the cover pressure-bonding section, creating a localized tight fit for the conductor tip. This local quality change ensures close contact and eliminates air gaps in the conductor region while the larger cover section maintains water-blocking capability.
2Reliability
If the conductor pressure-bonding section has a smaller diameter, then close contact with conductor tip is achieved, but the insertion of conductor tip portion becomes difficult
Solution Approach 1:
The pressure-bonding section is segmented into two parts with different diameters: the cover pressure-bonding section with larger diameter for easy insertion of the insulating cover, and the conductor pressure-bonding section with smaller diameter for close contact with the conductor tip. This segmentation resolves the contradiction between insertion ease and contact quality.
Solution Approach 2:
The conductor pressure-bonding section is nested within the cover pressure-bonding section, creating a concentric structure where the smaller conductor section is surrounded by the larger cover section. This nested arrangement allows the insulating cover to be inserted easily through the larger outer section while the conductor tip achieves close contact in the smaller inner section.
3Ease of manufacture
If a single uniform diameter pressure-bonding section is used, then manufacturing is simplified, but stable conductivity cannot be achieved due to air gaps
Solution Approach 1:
The pressure-bonding section is segmented into two functional sections with different diameters: the cover pressure-bonding section and the conductor pressure-bonding section. This segmentation enables close contact with the conductor tip to eliminate air gaps while maintaining a relatively simple manufacturing process through integral formation.
Solution Approach 2:
The diameter parameter of the pressure-bonding section is changed along its length, creating a tapered or stepped profile where the diameter transitions from larger (cover section) to smaller (conductor section). This parameter change enables close contact for stable conductivity while the overall structure remains manufacturable through standard forming processes.
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3
AI summary
In a female crimp terminal 10 having a pressure-bonding section 30 which allows pressure-bonding and connection of at least a conductor tip 201a in an insulated wire 200 obtained by coating a conductor 201 with an insulating cover 202 and having the conductor tip 201a in which the conductor 201 is exposed by peeling off the insulating cover 202 in a tip side, the pressure-bonding section 30 is constructed by arranging a conductor pressure-bonding section 30b and a cover pressure-bonding section 30a from a tip side to a base end side in a long length direction X in this order, the conductor pressure-bonding section 30b pressure-bonding the conductor tip 201a, and the cover pressure-bonding section pressure-bonding a conductor tip portion 202a in the tip side of the insulating cover 202, the cover pressure-bonding section 30a is formed into a hollow shape which can surround the conductor tip portion 202a, and the conductor pressure-bonding section 30b is formed to have a smaller diameter than the cover pressure-bonding section 30a, and is formed into a hollow shape which can surround the conductor tip 201a.