Terminal-Equipped Electrical Wire Crimped Barrel Waterproofing
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Solution Overview
Problem
Conventional terminal-equipped electrical wires face challenges in achieving high productivity and sustained reliability of electrical connections due to galvanic corrosion between dissimilar metals, which requires complex sealing processes that complicate mass production.
Innovation Solution
A terminal-equipped electrical wire design featuring a crimped barrel portion with a high compression region that suppresses water contact and corrosion, allowing the conductor core wire to corrode preferentially at the exposed end, thereby delaying corrosion of the covered portion and maintaining electrical connection reliability without the need for a seal member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a seal member is provided in the barrel portion to isolate the conductor core wire from water, then galvanic corrosion is suppressed and reliability is maintained, but the sealing material must be attached to each terminal fitting with precise positioning, reducing productivity
Solution Approach 1:
The invention removes the seal member from the barrel portion entirely, extracting the waterproofing function from a separate component and replacing it with the barrel portion's own structural features (depressed portions and overlapping ends) that provide waterproofing without requiring additional sealing materials
Solution Approach 2:
The waterproofing function is merged into the barrel portion structure itself. The depressed portions and overlapping end configuration integrate waterproofing capabilities directly into the terminal fitting, eliminating the need for separate seal members and simplifying the overall structure
2Object-affected harmful factors
If the barrel portion is crimped to cover the conductor core wire, then water contact is suppressed, but the crimping process requires high compression force that may damage the conductor core wire
Solution Approach 1:
The barrel portion features depressed portions that create localized high compression regions with greater compression rates, while other regions maintain lower compression rates. This local differentiation allows effective water sealing at critical areas without subjecting the entire conductor core wire to excessive compression forces that would cause damage
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 enhances productivity by eliminating the need for sealing materials and ensures sustained reliability of electrical connections through controlled corrosion and increased adhesion between the terminal fitting and conductor core wire, maintaining functionality for the service life of the wire.
Implementation Method 1
This terminal-equipped electrical wire is likely to have water caught between the core wire of the electrical wire and the terminal fitting, which are the dissimilar metals, in which case the water acts as an electrolytic solution, resulting in galvanic corrosion (contact corrosion of dissimilar metals).
Data Source
AI summary
A terminal-equipped electrical wire includes an electrical wire and a terminal fitting that is attached to the electrical wire. In the electrical wire, the terminal fitting includes a barrel portion crimped to a conductor core wire exposed from the electrical wire, and a contact portion to be connected to a mating terminal. The barrel portion is a cylindrical plate-like body in which one end and the other end overlap with each other after crimping, and has a plate-like body including a proximal end portion covering a sheath of the electrical wire, a distal end portion covering the conductor core wire away from the proximal end portion, and an intermediate portion connecting the proximal end portion and the distal end portion and covering the conductor core wire so as to isolate it from the outside between the proximal end portion and the distal end portion.