Terminal Crimping Structure Using Flat Pressing Projections
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Solution Overview
Problem
Existing terminal crimping methods can damage electric wire conductors due to high stress concentration at the crimping points, particularly when using dies with projecting dimensions that are large in one direction, leading to potential damage to the conductor and reduced shielding effectiveness.
Innovation Solution
A terminal crimping method and structure that uses dies with flat-shaped pressing projections, where the length in one axial direction is longer than the other, to increase the crimping area and reduce stress concentration, and aligns the crimp recess portions orthogonally to the electric wire axis, allowing for a more compact terminal design and reduced damage to braided shield conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If pressing projections with large projecting dimensions are used to increase crimping force, then crimping force is improved, but stress concentration increases causing damage to the conductor
Solution Approach 1:
The pressing projection is designed with a flat shape having different dimensions in different directions (longer in one axial direction, shorter in the other), creating non-uniform local contact characteristics that distribute stress more evenly across the terminal's crimping surface while maintaining sufficient crimping force
Solution Approach 2:
The pressing projection extends in the axial direction rather than only in the radial direction, utilizing the axial dimension to increase contact area and distribute stress along the length of the projection, thereby reducing stress concentration at any single point
2Force
If pressing projections are aligned parallel to the electric wire axis, then crimping force is maximized, but the terminal axial length increases
Solution Approach 1:
The pressing projection is designed with asymmetric orientation relative to the wire axis, with its longitudinal direction aligned orthogonally to the wire axis. This asymmetric configuration allows the longer dimension of the projection to extend in the radial direction, maximizing contact area and crimping force while keeping the axial projection minimal
3Ease of manufacture
If conventional crimping methods are used, then crimping process is simple, but damage to shield conductor occurs reducing shielding effectiveness
Solution Approach 1:
The flat-shaped pressing projection creates localized crimping zones with controlled stress distribution, preventing excessive force concentration that would damage the braided shield conductor structure, thereby maintaining shielding effectiveness while preserving the simplicity of 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 approach effectively secures a sufficient crimping force while minimizing damage to the electric wire conductor and enhancing shielding effectiveness by distributing the force more evenly and reducing the terminal's axial length.
Implementation Method 1
caulking and crimping the fixing cylinder portion by a pair of dies including pressing projections each having a flat shape
Implementation Method 2
caulking the fixing cylinder portion by the pressing projections to form crimp recess portions
Data Source
AI summary
A terminal crimping method includes covering an end portion of an electric wire with a fixing cylinder portion of a terminal, caulking and crimping the fixing cylinder portion by a pair of dies including pressing projections each having a flat shape in which a length in one axial direction is longer than a length in the other axial direction orthogonal to the one axial direction in a plan view, and caulking the fixing cylinder portion by the pressing projections to form crimp recess portions, in the caulking and crimping the fixing cylinder portion.