Self-Locking Crimp Seam for Thin-Stock Connection Reliability
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Solution Overview
Problem
Conventional crimp connections suffer from lack of robustness under mechanical and torsional stresses, leading to potential failure at the seam, reduced crimping forces, and increased susceptibility to corrosion, especially when using thin stock for cost savings and miniaturization.
Innovation Solution
A crimp design featuring a self-locking wing and pocket mechanism that interlocks during crimping, providing additional mechanical and electrical robustness by creating a clinch connection and distributing compressive forces effectively, even with thinner stock thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thinner stock is used for cost savings and miniaturization, then manufacturing cost decreases and device size reduces, but mechanical robustness and electrical connection reliability deteriorate under mechanical and torsional stresses
Solution Approach 1:
The crimp connection is segmented into multiple independent crimping zones along the longitudinal seam, with each zone containing alternating male and female interlocking elements. This segmentation distributes mechanical and electrical stresses across multiple discrete locations rather than concentrating them at a single seam line, thereby maintaining connection reliability even with thinner stock material.
Solution Approach 2:
The patent applies local quality by creating alternating male and female interlocking elements at specific locations along the longitudinal seam. These localized features provide enhanced mechanical interlocking and electrical contact precisely where the seam is most vulnerable to stress, while the rest of the thin-stock crimp barrel maintains its reduced thickness for cost and size benefits.
2Device complexity
If conventional crimping is used, then manufacturing process is simple, but mechanical robustness under torsional stresses deteriorates due to seam failure
Solution Approach 1:
The male and female interlocking elements are pre-formed as integral features of the crimp barrel and contact during the stamping or drawing process, before the actual crimping operation. This preliminary formation ensures that the interlocking geometry is precisely defined and positioned, enabling the thin-stock crimp to achieve enhanced mechanical robustness without requiring additional post-crimping operations or complex assembly steps.
Solution Approach 2:
The patent effectively creates a composite structure by combining the crimp barrel material with interlocking elements of potentially different material properties or treatments. The alternating male and female elements can be formed from the same stock material but with localized work hardening or coating, creating a composite-like structure that enhances torsional strength while maintaining overall thin-stock construction.
3Strength
If additional form-fitting elements are provided to improve force connection, then mechanical connection strength improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges multiple functions into the alternating male and female interlocking elements: they provide mechanical interlocking to prevent seam separation, create electrical contact paths for current flow, and distribute crimping forces across multiple zones. This consolidation of mechanical and electrical functions into single integrated features enhances force connection strength without proportionally increasing structural complexity.
Solution Approach 2:
The interlocking elements serve multiple purposes simultaneously: they act as mechanical locks to prevent crimp barrel separation, provide electrical contact points for conductor connection, and distribute mechanical stresses during both crimping and service. This multi-functionality allows a single structural feature to address multiple performance requirements, improving force connection strength while limiting complexity growth.
Data Source
AI summary
A crimp includes a crimp barrel having a base, a first side wall extending from the base, and a second side wall extending from the base opposite to the first side wall, a self-locking wing on the first side wall, and a self-locking pocket on the second side wall. The self-locking wing is adapted to lock with the self-locking pocket.