Terminal-Equipped Wire Crimping with Core Confirmation Opening
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Solution Overview
Problem
Existing methods for connecting terminals to wires, such as aluminum to copper, are prone to electrolytic corrosion due to moisture exposure when the core is not properly secured within the wire barrel, and ensuring the necessary crimping length and fixing force is challenging.
Innovation Solution
A terminal-equipped wire design featuring a wire barrel with barrel pieces extending from both sides of a bottom plate, allowing the core to be crimped with a confirmation opening formed to ensure the core is fully secured within the anticorrosive, preventing electrolytic corrosion and ensuring a sufficient crimping length and fixing force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire barrel is caulked to cover the tip of the core to prevent electrolytic corrosion, then the anticorrosive function is improved, but it cannot be confirmed whether the necessary caulking length is ensured and fixing force is secured
Solution Approach 1:
The patent uses visual indication through a transparent or translucent portion in the wire barrel to show the position of the core tip. This allows operators to visually confirm whether the core is properly positioned and caulked without disassembly, resolving the contradiction between ensuring corrosion protection and verifying caulking quality.
Solution Approach 2:
The patent introduces an intermediary visual indicator system (transparent portion and visible core tip) that mediates between the internal caulked structure and external inspection. This intermediary allows non-destructive verification of the caulking quality while maintaining the integrity of the anticorrosive sealing.
2Manufacturing precision
If the core is placed with tip projecting from front edge of wire barrel, then caulking length can be confirmed, but electrolytic corrosion may occur due to moisture exposure
Solution Approach 1:
The transparent or translucent portion allows visual confirmation that the core tip has been properly caulked while maintaining the sealed structure. The visual indicator shows that the core is positioned correctly without requiring it to protrude, thus preventing moisture exposure while maintaining manufacturing precision.
Solution Approach 2:
The wire barrel acts as a flexible sealing structure that can be caulked around the core while maintaining visibility through the transparent portion. This allows the barrel to conform to the core position and provide both mechanical securing and environmental sealing simultaneously.
3Reliability
If the wire barrel is caulked to cover up to the tip of the core to prevent electrolytic corrosion, then the anticorrosive function is improved, but the fixing force may be insufficient
Solution Approach 1:
The visual indication system allows operators to verify that the core is properly positioned within the wire barrel before caulking. This ensures optimal positioning for both corrosion protection and mechanical bonding, allowing the full fixing force to be achieved while maintaining the anticorrosive seal.
Solution Approach 2:
The patent enables preliminary visual confirmation of core positioning before the caulking process is completed. This preliminary action ensures that the core is correctly positioned to maximize both the anticorrosive sealing and the mechanical fixing force, avoiding the need to compromise either function.
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
The design effectively prevents electrolytic corrosion by ensuring the core is fully covered by the anticorrosive, securing the necessary crimping length and fixing force without requiring redesign of the terminal, while allowing precise formation of the core confirmation opening without excessive stress.
Implementation Method 1
crimping the barrel pieces to bend and embrace the core
Implementation Method 2
If moisture is present between contact parts of these two metals, both metals are dissolved in the form of ions into the moisture, and electrolytic corrosion occurs to corrode base metals by an electrochemical reaction
Data Source
AI summary
A terminal-equipped wire (X) includes a wire (10) with a core (11) covered by with insulation coating (12). A terminal (20) including a wire barrel (23) is crimped onto the core (11) exposed at an end of the wire (10). An anticorrosive (35) is attached to cover the crimped wire barrel (23). The wire barrel (23) has barrel pieces (23B) extending from side edges of a bottom plate. The core (11) is placed on the bottom plate so that a tip of the core (11) is retracted rearwardly of front edges of the barrel pieces (23B) and the barrel pieces (23B) are crimped to embrace the core (11) while extending ends of the barrel pieces (23B) butt against each other. A core confirmation opening (30) is formed in a front of the crimped wire barrel (23) by widening an interval between corresponding butting parts of the barrel pieces (23B).