Two-Layer Crimp Structure for Ultra-Fine Single-Wire Conductors
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Solution Overview
Problem
Conventional crimp connection terminals struggle to reliably connect and fix ultra-fine conductors made of single copper alloy wires, due to insufficient flexibility and plasticity, leading to uneven caulking forces and mechanical/electrical reliability issues.
Innovation Solution
A conductor crimp structure using a connection terminal with a crimping piece having a two-layer structure and void portions, along with pressing portions at three locations to concentrate strong forces and non-pressing portions to maintain conductor flexibility, ensuring reliable caulking and fixing of single-wire conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional terminal crimping piece is used to crimp an ultra-fine single-wire conductor, then the conductor can be fixed mechanically, but the caulking force is uneven and insufficient, leading to poor mechanical fixing force and electrical conductivity
Solution Approach 1:
The crimping piece features localized pressing portions with concentrated pressing forces at specific locations, rather than uniform distribution. This local quality approach creates high-density contact points that penetrate through oxide layers and achieve reliable electrical conductivity while maintaining adequate mechanical fixing force for ultra-fine single-wire conductors
Solution Approach 2:
The crimping piece is divided into multiple pressing portions and non-pressing portions along its length. This segmentation allows different regions to serve different functions: pressing portions provide concentrated force for penetration and conductivity, while non-pressing portions maintain conductor flexibility and prevent excessive deformation
2Stability of the object's composition
If a conventional terminal crimping piece applies uniform caulking force to an ultra-fine single-wire conductor, then the conductor can be held firmly, but the conductor's flexibility and plasticity are insufficient, causing uneven caulking and unreliable fixation
Solution Approach 1:
The crimping piece implements local quality by providing pressing portions at specific locations rather than uniform caulking along the entire contact length. This creates zones of high compression for stability at pressing portions, while non-pressing portions preserve conductor flexibility and prevent excessive rigidification
Solution Approach 2:
The design creates a dynamic balance between fixation and flexibility by alternating pressing and non-pressing portions. The pressing portions provide localized rigid fixation points, while the non-pressing portions maintain overall conductor flexibility, allowing the conductor to remain somewhat compliant while achieving reliable mechanical fixation
3Reliability
If strong pressing force is applied to remove oxides and sulfides from the conductor surface, then electrical conductivity improves, but the conductor with small diameter made of single wire is difficult to crimp favorably
Solution Approach 1:
The crimping piece concentrates pressing forces at specific localized pressing portions rather than applying diffuse force across the entire conductor. This local concentration achieves sufficient force to penetrate oxide and sulfide layers for good electrical conductivity, while the limited contact area at these portions minimizes overall deformation and maintains crimping quality for delicate ultra-fine conductors
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 proposed crimp structure achieves reliable mechanical fixing and electrical conductivity for single-wire conductors, while maintaining the conductor's elasticity, thus enhancing overall mechanical and electrical reliability.
Implementation Method 1
pressing portions for locally concentrating strong pressing forces on the conductor are provided at three locations
Implementation Method 2
pressing portions for locally concentrating strong pressing forces on the conductor are provided at three locations
Implementation Method 3
non-pressing portions are provided between the conductor and the crimping pieces at three locations adjacent to the pressing portions
Implementation Method 4
This enables the conductor to be fixed by reliable caulking, resulting in mechanical/electrical reliability
Data Source
AI summary
A conductor made of a single wire is crimped and fixed securely by a conductor crimping portion to achieve the reliability of electrical connection. In a conductor crimping portion, first and second crimping pieces each having a two-layer structure of an inner layer plate and an outer layer plate are raised in a U-shape in advance. A conductor made of a single wire is disposed between the crimping pieces. The outer layer plate and the inner layer plate are pressed to caulk and fix the conductor from all sides. In caulking the conductor, pressing forces in two directions, which are a pressing force from below toward the center of the conductor and a pressing force from obliquely upward toward the center of the conductor, are applied to form non-pressing portions between the inner layer plate and the conductor between pressing portions making contact with the conductor.