Self-Locking Crimp Barrel for Torsion-Resistant Wire Connections
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Solution Overview
Problem
Conventional crimp connections suffer from lack of robustness under mechanical and torsional stresses, leading to potential failure and increased electrical resistance due to relative movement of wires and corrosion, especially when using thinner stock materials which compromise both mechanical and electrical performance.
Innovation Solution
A self-locking hooked crimp connection design with interlocking seams, featuring a crimp barrel with self-locking wings and hooked pockets that lock together to enhance mechanical and electrical robustness, preventing deflection and relative movement of wires, even with thinner stock thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional crimp connections are made with thinner stock materials to reduce cost and improve manufacturing, then manufacturing suitability and cost-effectiveness are improved, but mechanical robustness and electrical reliability deteriorate under mechanical and torsional stresses
Solution Approach 1:
The crimp connection is segmented into distinct functional zones: a compression zone with higher stock thickness for electrical contact and a reinforcement zone with additional material for mechanical strength. This segmentation allows thinner overall stock while maintaining both electrical reliability and mechanical robustness through localized material distribution.
Solution Approach 2:
The crimp barrel exhibits local quality variations in stock thickness along its length. The compression zone has optimized thickness for electrical conductivity, while the reinforcement zone has increased thickness for mechanical strength. This non-uniform thickness distribution resolves the contradiction by providing appropriate material properties at different locations rather than uniformly thick stock throughout.
2Ease of manufacture
If conventional crimp connections are made with thinner stock materials to reduce cost and improve manufacturing, then manufacturing suitability and cost-effectiveness are improved, but mechanical robustness deteriorates under mechanical and torsional stresses
Solution Approach 1:
The crimp connection is segmented into distinct functional zones: a compression zone with higher stock thickness for electrical contact and a reinforcement zone with additional material for mechanical strength. This segmentation allows thinner overall stock while maintaining both electrical reliability and mechanical robustness through localized material distribution.
Solution Approach 2:
The crimp barrel exhibits local quality variations in stock thickness along its length. The compression zone has optimized thickness for electrical conductivity, while the reinforcement zone has increased thickness for mechanical strength. This non-uniform thickness distribution resolves the contradiction by providing appropriate material properties at different locations rather than uniformly thick stock throughout.
3Device complexity
If conventional crimp connections are used without additional reinforcement, then device complexity is reduced, but electrical resistance increases due to relative movement of wires and corrosion
Solution Approach 1:
The reinforcement elements are merged with the crimp barrel as integral components formed from the same material during the crimping process. This integration eliminates the need for separate reinforcement parts, maintaining device simplicity while providing enhanced protection against wire movement and corrosion through the combined structural strength of the integrated design.
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 self-locking hooked crimp connection provides increased robustness and reliability against mechanical and torsional stresses, maintaining a secure electrical and mechanical connection while allowing for thinner stock materials, thus improving manufacturing suitability and cost-effectiveness.
Implementation Method 1
the first side wall is provided with at least one self-locking wing and the second side wall is provided with at least one self-locking hooked pocket such that the self-locking wing of the first side wall is adapted to lock with the self-locking hooked pocket of the second side wall
Implementation Method 2
the crimping stamp descends onto the anvil and bends the crimp flanks around the electrical conductor in order to compress it tightly, and to fix it in a force-locking manner with the crimping barrel
Implementation Method 3
In the transition area from the crimp base to the crimp side-walls, the so-called crimping roots, as well as laterally at the crimp side-walls, zones of high bending stresses are formed in the crimp barrel
Data Source
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AI summary
A crimp for connecting wires is provided with a self-locking wing and a self-locking hooked pocket such that the self-locking wing is adapted to lock with the self-locking hooked pocket creating a crimp connection of high robustness against mechanical, torsional and thermal stresses. In particular, a crimp (2, 6) for connecting wires comprises at least one crimp barrel, wherein the crimp barrel comprises at least one base and at least two opposing side walls (4a, 4b) extending from the base, wherein the first side wall (4a) is provided with at least one self-locking wing (11a, 11b, 111a, 111b) and the second side wall (4b) is provided with at least one self-locking hooked pocket (10a, 10b, 100a, 100b) such that the self-locking wing of the first side wall is adapted to lock with the self-locking hooked pocket of the second side wall.