Terminal-Equipped Electric Wire Resin Gap Sealing
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Solution Overview
Problem
Conventional terminal-equipped electric wires face challenges in improving anticorrosion performance while maintaining a low terminal height, as applying resin to the covering crimp portion can increase the terminal height and compromise electrical performance.
Innovation Solution
A terminal-equipped electric wire design featuring a crimp terminal with a core wire crimp portion and a covering crimp portion, where the covering crimp portion includes a bottom wall and crimping pieces that are in close contact with the covering, and a resin that covers the gap formed by the crimping pieces, shielding the core wire from external space without increasing the terminal height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin is applied to the covering crimp portion to improve anticorrosion performance, then the terminal height increases, but electrical performance deteriorates
Solution Approach 1:
The resin is applied selectively only to specific areas where gaps exist between the crimping pieces and the covering, rather than covering the entire terminal. This localized application provides corrosion protection precisely where needed while avoiding unnecessary height increase across the whole terminal structure.
Solution Approach 2:
The resin fills gaps in the radial dimension (between crimping pieces and covering) rather than adding height in the axial dimension. This dimensional shift allows corrosion protection to be achieved without increasing terminal height, effectively moving the protective function from the height direction to the radial gap-filling direction.
2Reliability
If resin is applied to cover the entire crimp portion, then anticorrosion performance improves, but manufacturing complexity increases
Solution Approach 1:
The resin application is localized to specific gap areas rather than covering the entire terminal surface. This reduces the amount of resin needed and simplifies the application process, making manufacturing less complex while still achieving adequate corrosion protection at critical interfaces.
Solution Approach 2:
Instead of applying resin to the entire terminal surface (excessive action), the invention applies resin only to the extent necessary to fill gaps and provide protection (partial action). This optimized approach reduces material usage and simplifies the manufacturing process while maintaining sufficient anticorrosion performance.
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 effectively enhances anticorrosion performance by sealing the gap between the crimping pieces with resin, preventing water infiltration and maintaining the existing terminal height, thus improving electrical reliability without increasing the terminal height.
Implementation Method 1
the resin closes a gap surrounded by a tip surface of the second crimping piece, an inner surface of the first crimping piece, and an outer surface of the covering, from the core wire crimp portion side
Data Source
AI summary
A terminal-equipped electric wire includes an electric wire having a core wire and a covering, a crimp terminal including a core wire crimp portion and a covering crimp portion, and a resin that integrally covers a range from a tip of the core wire to side surfaces of the covering crimp portion and that shields the core wire from an external space. The covering crimp portion has each of the bottom wall portion, the first crimping piece, and the second crimping piece coming in close contact with the covering, and the covering crimp portion is crimped to the covering with the first crimping piece laid over a tip portion of the second crimping piece. The resin closes a gap surrounded by the tip surface of the second crimping piece, an inner surface of the first crimping piece, and an outer surface of the covering.