Terminal Crimping Structure for Electric Wire Connection
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Solution Overview
Problem
Conventional connection structures between electric wires and terminals experience increased electrical resistance due to a large number of strands not in direct contact with the terminal, especially when the strands are made of materials like aluminum that form oxide films, leading to higher resistance.
Innovation Solution
A connection structure featuring a terminal with a bottom-plate portion and pair of core-wire-crimping pieces that extend to approach each other at the proximal-end, contact at an intermediate portion, and separate at the distal-end, with at least one portion of the distal-end extending in a different direction, effectively increasing the number of strands in direct contact and reducing resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large number of strands are used in the core wire, then the current carrying capacity is improved, but the electrical resistance increases due to more strands not in direct contact with the terminal
Solution Approach 1:
The core-wire-crimping piece is divided into multiple contact portions at its distal end, allowing multiple strands to be in direct contact with the terminal simultaneously. This segmentation of the crimping structure enables better distribution of electrical contact points across all strands, reducing overall electrical resistance while maintaining high current carrying capacity.
Solution Approach 2:
The distal end of the core-wire-crimping piece is designed with varying contact characteristics - some portions extend in different directions to contact specific strands. This local differentiation ensures that each strand finds an appropriate contact point, optimizing electrical conductivity at the strand level while maintaining the overall structural integrity of the connection.
2Weight of moving object
If strands are made of aluminum to reduce weight and cost, then the weight and manufacturing cost are reduced, but the electrical resistance increases due to oxide film formation
Solution Approach 1:
The oxide film on aluminum strands, which normally increases resistance, is converted into a beneficial element. The crimping structure's multiple contact portions ensure that even with oxide films present, sufficient direct contact is maintained between strands and the terminal, keeping resistance low. The design accepts the oxide film's presence while compensating for its resistive effect through increased contact points.
3Ease of manufacture
If the core-wire-crimping piece has a simple linear structure, then the manufacturing is simplified, but the number of strands in direct contact is reduced
Solution Approach 1:
The core-wire-crimping piece features a segmented distal end with multiple contact portions instead of a simple linear structure. This segmentation is achieved through controlled forming processes that create the multi-directional extensions, balancing manufacturing feasibility with the need for multiple strand contact points to reduce electrical resistance.
Data Source
AI summary
A connection structure between an electric wire and a terminal has an electric wire including a core wire with strands, and a terminal including a bottom-plate portion and a pair of core-wire-crimping pieces, which protrude from both edges of the bottom-plate portion and each distal-end portion of the pair of core-wire-crimping pieces being divided into a plurality of portions, the terminal enclosing and holding the core wire by the bottom-plate portion and the pair of core-wire-crimping pieces. The pair of core-wire-crimping pieces extends in directions to approach each other at a proximal-end portion, is in contact with each other at an intermediate portion, and extends in directions to be separated from each other at the distal-end portion. At least one portion of the plurality of portions of each distal-end portion of the pair of core-wire-crimping pieces extend in a different direction from other portions of the distal-end portion.