Electric-Wire Terminal Intermediate Crimping for Fluid Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric-wire-equipped terminals require lengthy processing times and multiple components due to the need for heat-shrinkable tubes and heat processing, which complicates the prevention of fluid entry into the wire.
Innovation Solution
The terminal design incorporates an intermediate crimp section that closely contacts the insulation coating and conductor without gaps, eliminating the need for heat-shrinkable tubes by simultaneously crimping the insulation coating, conductor, and intermediate crimp sections to prevent fluid entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heat-shrinkable tube and water sealant are used to cover the conductor, then fluid entry prevention is improved, but processing time increases and component count increases
Solution Approach 1:
The patent extracts and eliminates the heat-shrinkable tube and water sealant components from the assembly, replacing them with a crimping structure that integrates sealing functionality directly into the terminal connection mechanism
Solution Approach 2:
The patent merges the sealing function with the crimping structure by designing the intermediate crimp section to simultaneously perform mechanical connection and fluid sealing, eliminating the need for separate sealing components
2Reliability
If a heat-shrinkable tube and water sealant are used to cover the conductor, then fluid entry prevention is improved, but the number of components increases
Solution Approach 1:
The patent merges the sealing function with the crimping structure by designing the intermediate crimp section to simultaneously perform mechanical connection and fluid sealing, eliminating the need for separate sealing components
Solution Approach 2:
The patent extracts and eliminates the heat-shrinkable tube and water sealant components from the assembly, replacing them with a crimping structure that integrates sealing functionality directly into the terminal connection mechanism
3Reliability
If heat processing is performed on the heat-shrinkable tube, then sealing reliability is improved, but processing time increases
Solution Approach 1:
The patent replaces the thermal processing system with a mechanical crimping system, where the intermediate crimp section applies mechanical pressure to create both the electrical connection and the fluid seal simultaneously, eliminating the need for heat processing
Solution Approach 2:
The patent merges the sealing function with the crimping structure by designing the intermediate crimp section to simultaneously perform mechanical connection and fluid sealing, eliminating the need for separate sealing components
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 configuration reduces processing time and component count while effectively preventing fluid entry into the electric wire, enhancing reliability and efficiency.
Implementation Method 1
an intermediate crimp section crimping the insulation coating and the conductor
Data Source
Figure 1A~1B
Figure 2~3
Figure 4A~4B
AI summary
An electric-wire-equipped terminal (2) and the method of manufacturing the wire-equipped terminal (2) includes an electric wire having a conductor (W1) including a plurality of strands and an insulation coating (W2) covering the conductor (W1), and a terminal (2) connecting the electric wire. The terminal (2) has an insulation-coating crimping section (6) crimping the insulation coating (W2); a conductor crimp section (7) crimping the conductor (W1) exposed to the outside by removing the insulation coating (W2); and an intermediate crimp section (8) disposed between the insulation-coating crimp section (6) and the conductor crimp section (7), crimping over the conductor (W1) exposed and the insulation coating (W2), and being in a state where there is no gap for water to enter inside the electric wire.