Terminal Wire Crimp Recess for Water-Stop Resin Durability
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Solution Overview
Problem
Conventional terminal-equipped electric wires face durability issues with water-stopping members due to the crimping force causing the core wire end to protrude, leading to thinner resin application and reduced durability, and existing solutions either fail to prevent liquid entry or do not effectively discharge adhering liquids.
Innovation Solution
A terminal-equipped electric wire design featuring a terminal fitting with a bottom wall and caulking pieces that crimp and caulk the core wire exposed part, including a concave area to manage the crimping force and maintain resin thickness, combined with a water-stopping member of curable resin to suppress liquid entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the core wire exposed part protrudes from the caulked and crimped part, then the crimping force can be applied to secure the connection, but the water-stopping member becomes thinner in the jumping part and durability deteriorates
Solution Approach 1:
The patent applies preliminary action by forming a recess in the bottom wall of the terminal fitting before the crimping process. This recess is specifically designed to accommodate the upward jumping of the core wire exposed part during crimping, preventing the wire end from protruding into the water-stopping member formation space and ensuring uniform resin thickness from the outset
Solution Approach 2:
The recess in the bottom wall acts as an intermediary structure that mediates between the crimping force and the water-stopping member formation. It provides a dedicated space for the core wire exposed part to jump into during crimping, thereby isolating the water-stopping member formation area from the mechanical deformation and ensuring uniform resin application
2Productivity
If a narrow groove is provided on the bottom wall to discharge liquid, then liquid discharge function is improved, but not all adhering liquid can be discharged and corrosion prevention is insufficient
Solution Approach 1:
The patent converts the potentially harmful protruding wire end into a beneficial feature by designing the recess to specifically receive it. The wire end that would otherwise damage the water-stopping member is now utilized to fill and seal the recess, creating an additional barrier against liquid entry while the groove discharges excess liquid
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 enhances the durability of the water-stopping member and effectively prevents liquid entry, maintaining anticorrosion performance and simplifying the resin application process while ensuring sufficient thickness and electric conduction quality.
Implementation Method 1
a water-stopping member formed of a curable resin material and covering an exposed part of the electric wire end in the terminal fitting from outside together with the terminal fitting
Data Source
AI summary
A terminal-equipped electric wire includes an electric wire, a terminal fitting, and a water-stopping member. The terminal fitting includes a bottom wall on which the electric wire end is placed, and a pair of core wire caulking pieces caulking and crimping a core wire exposed part in a state where a front end of the core wire exposed part protrudes, and the bottom wall includes a concave part that continues from a place facing the front end side of the core wire exposed part in the pair of core wire caulking pieces to the tip of a front end surface of the front end of the core wire exposed part, and receives the bottom wall side ranging from a place where the core wire exposed part is caulked and crimped by the end parts of the pair of core wire caulking pieces to the front end surface.