Terminal Assembly Wire Retention Seal Axial Positioning
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Solution Overview
Problem
Existing terminal assemblies face issues with inconsistent sealing and improper positioning during crimping due to shifting components, leading to poor electrical connections and sealing failures.
Innovation Solution
A terminal assembly with a wire retention seal that includes a terminal mounting flange and a wire retention sleeve, which axially secures the seal to the terminal and interferes with the wire to retain it before crimping, ensuring proper alignment and sealing between the terminal and wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a seal is compressed with the wire barrel during crimping to conform around the wire, then sealing is achieved, but the terminal and seal shift or move relative to the wire during handling and loading, leading to improper positioning and poor connection
Solution Approach 1:
The wire retention seal is pre-installed in the wire barrel before crimping, and the wire is pre-positioned within the seal's retention features. This preliminary arrangement ensures that both the seal and wire are correctly positioned before the crimping operation begins, eliminating shifting during handling and loading while maintaining sealing effectiveness.
2Reliability
If an O-ring is positioned in a seal cavity to provide sealing, then sealing between wire and terminal is achieved, but the O-ring provides inconsistent seal performance and complete failure when displaced out of the seal cavity during wire insertion
Solution Approach 1:
The wire retention seal acts as an intermediary component between the wire and the terminal's seal cavity. It features a retention groove that captures the wire and prevents displacement, while its own sealing features provide the actual sealing interface. This intermediary structure eliminates the problems of O-ring displacement and inconsistent sealing performance.
3Productivity
If the terminal and seal are crimped onto the wire in a single operation, then efficiency is improved, but improper positioning during crimping leads to poor electrical connection and poorly sealed connection
Solution Approach 1:
The wire retention seal pre-positions the wire within the wire barrel before crimping begins. The retention groove and flange structure ensure the wire is correctly located, allowing the single-crimp operation to achieve both efficient production and high connection quality without shifting or misalignment.
Data Source
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AI summary
A terminal assembly (100) including a terminal (101) having a wire barrel (140) configured to be crimped to a wire (102) and a mating segment (144) configured to be mated to a mating component. The terminal assembly (100) including a wire retention seal (110) received in the wire barrel (140). The wire retention seal (110) having a terminal mounting flange (112) engaging the wire barrel (140) to axially secure the wire retention seal (110) to the terminal (101). The wire retention seal (110) has a wire retention sleeve (114) defining a wire bore (122) configured to receive an end (108) of the wire (102). The wire retention sleeve (114) is configured to interfere with the wire (102) to axially retain the wire retention seal (110) on the end of the wire (102) prior to crimping the wire barrel (140) to the wire (102)