Stepped-Recess Crimp Connector for Low-Resistance High-Current Joints
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Solution Overview
Problem
Existing crimp connectors face challenges in achieving low electrical contact resistance for high electrical currents, particularly for conductors like stranded wires carrying several hundred amperes.
Innovation Solution
A crimp connector design featuring a groove-shaped recess in the connection zone with layered sheets and a crimp clamp that encloses the conductor, utilizing a separate crimp clamp component to secure the conductor within a stepped recess, enhancing mechanical and electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional crimp connectors without groove-shaped recesses are used, then the device complexity is lower, but the electrical contact resistance is high and mechanical retention is insufficient
Solution Approach 1:
The connection zone is segmented into multiple layered sheets (at least three layers) stacked together, with groove-shaped recesses formed in specific layers. This segmentation allows the conductor to be held at multiple levels and contact multiple sheet surfaces, reducing electrical contact resistance while maintaining a relatively simple overall structure.
Solution Approach 2:
The invention transitions from a single-plane connection to a multi-layered three-dimensional structure. The groove-shaped recesses are formed in specific layers of the stacked sheets, creating vertical dimensionality that enhances both mechanical retention and electrical contact without significantly increasing horizontal complexity.
2Strength
If the crimp clamp encloses the conductor completely, then the mechanical retention is improved, but the ease of operation during assembly is reduced
Solution Approach 1:
The groove-shaped recesses are pre-formed in the layered sheets before the crimping operation. The conductor is positioned within these pre-formed grooves, which guide and secure it during the crimping process. This preliminary structuring ensures proper conductor placement and enhances mechanical retention while simplifying the assembly operation.
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 design achieves a mechanically tight and electrically conductive connection with low contact resistance, suitable for high electrical currents and voltages, ensuring secure retention of the conductor.
Implementation Method 1
The tabs are bent around the electrical conductor to form a crimp clamp and are then crimped tightly. The crimp clamp, by crimping, i.e., by plastic deformation of the crimp clamp, clamps the electrical conductor within itself
Implementation Method 2
reduces electrical contact resistance between the crimp connector and the electrical conductor by molding the electrical conductor to the recess in the connection zone of the crimp connector when the electrical conductor is crimped
Data Source
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AI summary
The invention proposes to design a crimp connector (1) for connecting an electrical conductor (3) with layered sheets (6, 9) which have recesses (10) of different widths in a connection zone (8) which form a channel-shaped depression (11) with a step-shaped cross-section as a receiving space for the electrical conductor (3).