Shield Connector Crimp Structure to Suppress Barrel Springback

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Solution Overview

Problem

The crimping process for fixing a second conductor to a first conductor in shield connectors can lead to springback, where the extending piece lifts from the outer surface of the first conductor, compromising the structural integrity and shielding performance.

Innovation Solution

A cable with terminal configuration that includes a tubular connecting portion with a depressed portion to allow the second conductor's barrel to be excessively deformed and crimped, ensuring it returns to a proper position, preventing improper crimping and maintaining shielding performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the extending piece of the second conductor is crimped to wind around the outer peripheral surface of the first conductor, then the second conductor can be fixed to the first conductor, but the extending piece is lifted from the outer surface of the first conductor due to springback

Engineering Contradiction:
Improvefixing strengthVSAvoidcrimping position accuracy
Core Design Contradiction:
StrengthVSManufacturing precision

Solution Approach 1:

The patent applies preliminary anti-action by forming a depressed portion (counter-sunk hole) in advance at the crimping position on the first conductor. This pre-prepared recessed structure anticipates and counteracts the springback effect that will occur during crimping, allowing the extending piece to be excessively deformed into the depressed portion and then return to the correct position, preventing it from being lifted away from the surface.

Inventive Principle:
Principle #9Preliminary anti-action

Solution Approach 2:

The patent changes the geometric parameter of the first conductor by introducing a depressed portion with a specific shape and depth. This structural parameter change creates a recessed space that accommodates the excessive deformation of the extending piece during crimping, enabling the metal extending piece to be pushed into the depressed portion and then spring back to the proper crimping position.

Inventive Principle:
Principle #35Parameter changes

2Strength

If locking claws are formed on the first conductor and locking holes on the second conductor, then the second conductor can be fixed to the first conductor, but the structure becomes complicated

Engineering Contradiction:
Improvefixing strengthVSAvoidconductor structure complexity
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the complex locking claw and locking hole structures from the conductor design. Instead of adding these complicated mechanical interlocking features, the invention uses a simpler approach where the extending piece is crimped into a depressed portion, maintaining fixing strength while significantly reducing structural complexity.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of creating protruding locking claws on the first conductor that engage with holes in the second conductor, the patent inverts the approach by creating a recessed depressed portion in the first conductor that receives the extending piece. This inversion simplifies the structure by eliminating the need for complex interlocking features while achieving the same fixing function.

Inventive Principle:
Principle #13The other way round (Inversion)

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

This configuration effectively suppresses springback, ensuring the second conductor remains at the correct crimping position, enhancing the structural integrity and shielding performance of the connector.

Implementation Method 1

there is a concern that the extending piece is lifted from the outer surface of the first conductor due to so-called springback of the extending piece deformed by crimping to slightly return to an initial state

Methodology Applied
Scientific EffectSpringback: Elastic Recovery

Data Source

PatentUS11848524B2Cable with connector including conductor connected to the cable
Publication Date: 2023.12.19 AUTONETWORKS TECH LTD
  • US11848524B2 patent drawing
  • US11848524B2 patent drawing
  • US11848524B2 patent drawing

AI summary

A cable with terminal disclosed by this specification is provided with a shielded cable 11 including a conductive shield portion 15 for covering outer peripheries of two coated wires 12 and a sheath portion 16 for covering an outer periphery of the shield portion 15, a first outer conductor 51 made of metal and including a tubular portion 52 in the form of a rectangular tube, and a second outer conductor 60 including plate-like fixing barrels 62 to be crimped to wind around an outer surface of the tubular portion 52 in a circumferential direction. The tubular portion 52 includes a depressed portion 57 arranged inside to radially face the fixing barrels 62 and allowing the fixing barrels 62 to be crimped by causing the fixing barrels 62 to be excessively deformed beyond proper crimping positions.