Structured Crimp Contact to Prevent Flank Edge Slippage
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Solution Overview
Problem
The issue with existing crimp contacts is the likelihood of the upper edge of the crimp flank slipping during the crimping process, leading to an unsatisfactory connection.
Innovation Solution
The crimp contact features structured regions on the inner sides of the crimp flanks, which include elevations or depressions, or a roughened surface, to interlock with the upper edge, preventing slippage and enhancing friction, and may include a wing for additional material to improve sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the crimp flank is made smooth and simple during crimping, then the crimping process is easier and faster, but the upper edge slips on the inner side leading to unsatisfactory connection
Solution Approach 1:
The inner side of the crimp flank is given a different surface quality (roughened or structured) only in the front region where the upper edge contacts, while the rest of the crimp flank remains smooth for easy crimping. This local differentiation increases friction at the critical contact point without complicating the overall crimping process.
2Reliability
If structured regions are added to the crimp flank to prevent slippage, then connection reliability improves, but manufacturing complexity increases
Solution Approach 1:
Instead of making the entire crimp contact complex, only the inner side of the crimp flank in the front region is structured or roughened. The rest of the crimp contact remains simple and smooth, minimizing manufacturing complexity while achieving the anti-slip function where needed.
Solution Approach 2:
The solution moves from considering only the geometric shape of the crimp flank to modifying its surface topology (roughness or micro-structure). This dimensional change at the surface level provides anti-slip functionality without adding bulk or structural complexity to the overall component.
3Force
If the upper edge strikes the inner side during crimping, then a frictional connection is created, but the upper edge may still slip causing unsatisfactory crimp connection
Solution Approach 1:
The inner side surface is locally modified with increased roughness or structural elements exactly where the upper edge strikes during crimping. This localized friction enhancement ensures that the striking action creates a reliable frictional connection that prevents slippage.
Solution Approach 2:
The solution replaces reliance on pure mechanical interlocking or geometric constraints with friction-based connection enhanced by surface properties. The roughened or structured surface creates friction that actively resists slippage during the crimping process.
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 design results in a secure, hermetically sealed crimp connection that reduces the risk of slippage and corrosion, especially when different metals are used, by increasing friction and providing a sealing agent to prevent moisture ingress.
Implementation Method 1
By way of the structural elements, an upper edge of each crimp flank is interlocked with its inner side during a crimping procedure. When the crimp flanks are crimped, a frictional connection and/or a form-fitting connection arises on account of the structured region
Data Source
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AI summary
The invention relates to a crimp contact for crimping a conductor having a crimpable crimp flank for enclosing the conductor after crimping, and a receptacle for the conductor, which receptacle extends in a longitudinal direction of the crimp contact up to a receiving end. The crimp flank extends in the longitudinal direction over the receiving end up to a front end, with a front region of the crimp contact being arranged between the receiving end and the front end. The crimp contact has at least one structured region in the front region.