Serrated Metallic Cap Crimping Terminal Waterproof Seal
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Solution Overview
Problem
Conventional connection structures between terminals and electric wires require fillers to prevent water ingress, increasing complexity and reducing practicality.
Innovation Solution
A crimping terminal connection structure featuring a U-shaped electric wire connection part with crimp pieces and a serrated metallic cap that bites into the conductor and insulating coating, ensuring waterproof sealing without the need for fillers, using the same metal as the terminal to prevent electrolytic corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a filler is used to prevent water ingress in the cap, then waterproofing is improved, but device complexity and control items increase
Solution Approach 1:
The invention extracts and eliminates the filler from the connection structure by replacing it with a serrated cap design. The serrations create mechanical interlocking with the conductor and insulating coating, forming a waterproof seal without requiring any filler material. This reduces device complexity and control items while maintaining waterproofing reliability.
Solution Approach 2:
The serrated cap structure serves itself to create the waterproof seal through its own geometric features. The serrations automatically interlock with the conductor and insulating coating during crimping, generating the waterproof barrier without needing external filler materials. This self-service mechanism simplifies the overall structure and reduces control requirements.
2Reliability
If different metals are used for the conductor and terminal (e.g., aluminum conductor with copper terminal), then electrical performance is improved, but electrolytic corrosion occurs when water is present
Solution Approach 1:
The invention converts the potential harm of water ingress into a beneficial sealing mechanism. The serrated cap structure is designed to be crimped over both the conductor and the insulating coating, creating a mechanical seal that prevents water from reaching the metal-to-metal interface. This eliminates electrolytic corrosion while preserving the electrical performance benefits of dissimilar metal connections.
Solution Approach 2:
The serrated cap structure acts as an intermediary barrier between the dissimilar metals (conductor and terminal). By crimping the cap over the insulating coating, it creates a physical separation that prevents water from contacting the metal interface, thereby eliminating electrolytic corrosion while allowing the dissimilar metal connection to maintain its electrical performance advantages.
Data Source
AI summary
In a connection structure of a crimping terminal to an electric wire, the crimping terminal having an electric connection part in the front thereof, and an electric wire connection part formed in substantially a U shape in cross-section view by having a base plate part, and a pair of electric wire crimp pieces upwardly extending from both lateral edges of the base plate part in the back of the electric connection part, a metallic cap whose inner periphery is provided with serrations is attached to a distal end of the electric wire so as to cover the range from an exposed conductor-to the portion of an insulating coating, and the conductor and the insulating coating of the electric wire are bitten into the serrations by crimping the electric wire crimp pieces so as to surround the cap.