Electrical Terminal Double Material Layer Crimping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-frequency electrical connectors face challenges in maintaining reliable connections in mechanically loaded, warm, and chemically aggressive environments, particularly in the automotive sector, where conventional connectors fail to provide robust and cost-effective solutions for long-term transmission of electrical power and data.
Innovation Solution
The electrical terminal features a crimping section with a double material layer region, where a first material layer is crimped onto a second layer, providing mechanical reinforcement and 360° attachment for coaxial cables, enhancing resistance against disconnection and allowing adaptation to different cable cross-sections through a double material layer region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional single-layer crimping structures are used, then manufacturing is simpler, but mechanical strength and resistance to disconnection are insufficient in harsh environments
Solution Approach 1:
The patent applies composite materials by combining two different material layers (first material layer and second material layer) in the crimping section. The first material layer provides mechanical reinforcement while the second material layer ensures electrical conductivity and corrosion resistance. This composite structure resolves the contradiction by achieving superior mechanical strength and environmental resistance without requiring completely new manufacturing processes, as each layer can be applied using conventional techniques.
Solution Approach 2:
The crimping section is segmented into multiple functional layers with distinct purposes. The first material layer is dedicated to mechanical reinforcement and structural integrity, while the second material layer handles electrical conductivity and corrosion protection. This segmentation allows each layer to be optimized for its specific function, resolving the contradiction between strength and complexity by distributing functions across separate layers rather than requiring a monolithic complex structure.
2Reliability
If robust mechanical reinforcement is added to resist disconnection in harsh environments, then connection reliability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The first material layer is applied in advance during the crimping process before final assembly. This preliminary reinforcement ensures that the mechanical strength is already in place before the connector undergoes service conditions, preventing disconnection issues from the outset. This approach improves reliability without requiring complex post-manufacturing interventions, as the reinforcement is integrated into the manufacturing flow.
Solution Approach 2:
The composite material structure allows each layer to be manufactured using optimized processes suited to its properties. The first material layer can be applied using processes optimized for mechanical strength, while the second layer uses processes optimized for conductivity and corrosion resistance. This resolves the contradiction by enabling specialized manufacturing for each function rather than requiring a single complex process.
3Speed
If connectors are designed for high-frequency transmission, then data transmission capability improves, but susceptibility to interference and disconnection in mechanically loaded environments increases
Solution Approach 1:
The composite material structure provides both mechanical reinforcement and electromagnetic shielding properties. The first material layer offers mechanical strength to resist vibration and physical stress, while the second conductive material layer provides electromagnetic shielding to protect high-frequency signals from interference. This resolves the contradiction by integrating both mechanical and electromagnetic protection functions into the crimping section structure.
Data Source
AI summary
An electrical terminal includes a contacting section and a crimping section arranged to a rear of the contacting section in an axial direction of the terminal. A first material layer of the crimping section is crimped directly onto a second material layer of the terminal or of the crimping section in a crimped state, forming a double material layer region.