Terminal-Equipped Wire With Projection Grip For Waterproofing
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Solution Overview
Problem
Conventional terminal-equipped wires require a lengthy production process and increased costs due to the need for a resin coating to provide waterproof and corrosion-proofing, which complicates the manufacturing process and raises device and material costs.
Innovation Solution
A terminal-equipped wire design featuring a terminal fitting with a grip and projection that penetrates the insulating coating to establish electrical continuity with the conductor, eliminating the need for resin coating and simplifying the manufacturing process by gripping the wire along its circumference and penetrating the coating to prevent water ingress and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin coating is applied to the terminal section to provide waterproof and corrosion-proofing, then the reliability of the terminal-equipped wire is improved, but the device complexity and manufacturing cost are increased
Solution Approach 1:
The patent removes the resin coating step from the manufacturing process entirely. Instead of applying resin to protect the terminal section, the invention uses the terminal fitting's own structure (grip and projection) to provide both electrical connection and environmental protection, extracting the protective function from a separate resin coating process.
Solution Approach 2:
The terminal fitting serves dual functions: it provides electrical connection through the projection and simultaneously provides waterproof/corrosion-proof protection through the grip structure. The terminal fitting protects itself and the connection without requiring external resin coating, achieving self-service protection.
2Reliability
If a resin coating is applied to the terminal section to prevent water ingress, then the corrosion-proof performance is improved, but the material cost and production time are increased
Solution Approach 1:
The patent extracts the protective function from the resin coating process and integrates it into the terminal fitting structure itself. The grip and projection design inherently prevents water ingress without requiring separate resin application, coating, or curing steps, thereby improving production efficiency.
Solution Approach 2:
The patent combines the electrical connection function and the environmental protection function into a single terminal fitting component. The projection provides electrical connection while the grip provides waterproof protection, merging multiple functions into one integrated structure that eliminates separate resin coating steps.
3Reliability
If the insulating coating is removed from the terminal section to expose the conductor, then the electrical connection is improved, but the risk of water ingress and galvanic corrosion is increased
Solution Approach 1:
The patent applies preliminary protective action by designing the terminal fitting with an integrated grip structure that covers and protects the terminal section before water or corrosion can penetrate. The grip is positioned to prevent water ingress from the outset, eliminating the need to remove insulating coating for protection purposes.
Solution Approach 2:
The terminal fitting acts as an intermediary structure between the conductor and the external environment. The grip portion serves as a mediator that physically blocks water and corrosive substances from reaching the conductor, while the projection establishes electrical connection, thus mediating between electrical connectivity and environmental protection.
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 waterproof and corrosion-proof performance by preventing water from reaching the conductor, reducing production costs, and extending the product's lifetime by eliminating the need for resin coating and simplifying the manufacturing process.
Implementation Method 1
a projection provided integrally with or independently from the grip and penetrating the insulating coating
Implementation Method 2
a grip for gripping the terminal section of the electric wire along a circumferential direction of the electric wire
Implementation Method 3
the electric wire is swaged with the rear legs 2A from outside of the insulating coating 1A, and the exposed conductor 1B is swaged with the front legs 2B
Data Source
AI summary
There is provided a terminal-equipped wire able to reduce a production cost and satisfy water proof and corrosion proof performances at a terminal section of the electric wire. The terminal-equipped wire includes: an electric wire having a conductor in an insulating coating; and a terminal fitting crimped to a terminal section of the electric wire. The terminal fitting includes: an electrical contact portion for connecting with a terminal fitting of the mating connector; and a wire connection portion for connecting with the terminal section of the electric wire continuing to the electrical contact portion. The wire connection portion includes: a grip for gripping the terminal section of the electric wire along a circumferential direction of the electric wire; and a projection penetrating the insulating coating. The conductor and the terminal fitting have electrical continuity with each other via the projection.