Terminal-Equipped Electric Wire with Non-Uniform Compression Terminal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional terminal-equipped electric wires have a high electrical resistance ratio at the contact portion, leading to increased local overheating and potential disconnection issues between the conductor and the compression terminal.
Innovation Solution
The terminal-equipped electric wire design features a conductor made from a material with higher tensile strength than the compression terminal, allowing for controlled compression deformation and a mutual pressing load that reduces the electrical resistance ratio, achieved by using aluminum as the primary material for the conductor and aluminum alloys for the compression terminal, with specific compositions and manufacturing processes to optimize contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the compression terminal and conductor are made of the same material or the terminal has lower tensile strength, then the compression process is simpler, but the electrical resistance ratio increases and reliability decreases
Solution Approach 1:
The compression terminal is designed with non-uniform wall thickness, where the pad portion (contact portion) has greater thickness and thus higher tensile strength compared to the barrel portion. This local quality variation ensures that the contact portion maintains superior electrical connection reliability while the overall structure remains manageable in complexity.
Solution Approach 2:
The patent changes the material parameter (tensile strength) by making the pad portion thicker than the barrel portion. This parameter change ensures that the contact portion has higher tensile strength than the conductor, which reduces the electrical resistance ratio and improves connection reliability during the compression process.
2Reliability
If the compression terminal has uniform wall thickness, then the manufacturing process is simpler, but the electrical resistance ratio increases due to insufficient contact pressure
Solution Approach 1:
The compression terminal features non-uniform wall thickness with the pad portion being thicker than the barrel portion. This local quality differentiation concentrates the compression force at the contact area, reducing electrical resistance without requiring complex multi-step manufacturing processes.
Solution Approach 2:
By changing the wall thickness parameter along the axial direction of the compression terminal, the patent achieves better contact pressure distribution. The thicker pad portion provides higher tensile strength and better electrical contact, while the varying thickness can be achieved through standard extrusion or drawing processes.
3Reliability
If the compression terminal is heavily compressed to reduce resistance, then the electrical resistance ratio decreases, but the holding force decreases and disconnection risk increases
Solution Approach 1:
The non-uniform wall thickness design concentrates the compression effect at the pad portion where electrical contact occurs, while the barrel portion maintains sufficient thickness to provide holding force. This local quality variation allows high compression at the contact point without compromising overall structural integrity.
Solution Approach 2:
By varying the wall thickness parameter along the terminal's length, the patent optimizes the balance between contact resistance and holding force. The thicker pad portion accommodates higher compression for better electrical contact, while the barrel portion retains adequate thickness to maintain mechanical holding strength.
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 results in a significantly reduced electrical resistance ratio, minimizing overheating and preventing disconnection between the conductor and the compression terminal, while maintaining a strong holding force through appropriate section area ratios.
Implementation Method 1
By inserting the exposed conductor into the compression terminal and then externally compressing the compression terminal, the compression terminal is fixed to the electric wire
Implementation Method 2
allowing for controlled compression deformation and a mutual pressing load that reduces the electrical resistance ratio
Implementation Method 3
maintaining a strong holding force through appropriate section area ratios
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A terminal-equipped electric wire (1) includes: an electric wire (2) including a conductor (3) formed of at least one element wire, and a covering (4) that covers an outer periphery of the conductor; and a compression terminal (5) fixed to an end of the conductor. The at least one element wire is made of a first material including aluminum as a main component. At least a part, which contacts the conductor, of the compression terminal is made of a second material including aluminum as a main component. The first material has a tensile strength greater than a tensile strength of the second material.