Universal Crimp Terminal With Compliant Metal Insert
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Solution Overview
Problem
The existing crimp terminal solutions require multiple sizes of connectors for different wire sizes, leading to complexity and potential weak connections due to incorrect selection, which can result in corrosion and breakage.
Innovation Solution
A universal crimp terminal assembly featuring a crimp cylinder with a metal strip insert having compliant fingers that can accommodate a wide range of wire sizes from 22 AWG to 10 AWG, allowing for a single size and style crimp cylinder to be used with various wire sizes and terminal types, by positioning the insert within the crimp cylinder and applying crimping force to secure the wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple crimp terminal sizes are used to accommodate different wire sizes, then compatibility with various wire sizes is improved, but device complexity increases
Solution Approach 1:
The crimp terminal is designed with a single barrel size that can accommodate multiple wire sizes (22 AWG to 10 AWG) through the use of an insert with compliant members that adapt to different wire diameters, eliminating the need for multiple barrel sizes
Solution Approach 2:
The terminal is divided into distinct components: a barrel, an insert with compliant members, and a mating end. The insert acts as an intermediary element that can be configured to work with different wire sizes within the same barrel, providing versatility without increasing overall device complexity
2Strength
If the correct connector size is selected for each wire size, then connection strength is improved, but ease of operation deteriorates due to selection complexity
Solution Approach 1:
A single universal barrel design with an adaptive insert eliminates the need for users to select from multiple barrel sizes, simplifying the operation while maintaining strong connections through the compliant members that automatically adapt to the wire size
3Ease of manufacture
If gaps or air pockets are formed during crimping, then ease of manufacture is improved, but reliability deteriorates due to corrosion and breakage
Solution Approach 1:
The insert with compliant members acts as a flexible intermediary between the wire and the barrel, ensuring complete contact and eliminating gaps or air pockets during crimping, which prevents moisture buildup and corrosion while maintaining manufacturing simplicity
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 solution provides a strong and reliable crimp connection across a wide range of wire sizes without the need for multiple connector sizes, ensuring high pullout strength and maintaining conductivity, thus reducing the risk of corrosion and breakage.
Implementation Method 1
the insert comprising a plurality of compliant members (e.g., fingers) connected in parallel at a base. The insert is positioned within an interior surface of the crimp cylinder such that the fingers extend toward the mating end of the electric terminal
Implementation Method 2
Crimping refers to mechanically joining, or cold-welding, wires to a piece of metal by deforming one or both and securing them to one another. The deformity pinches the wire to hold it in place resulting in a crimp
Data Source
AI summary
An electric connector terminal assembly which allows numerous different terminal connector ends and wire diameters to be connected to a single size and type crimp cylinder using an rolled metal strip insert. Preferably, the metal strip is made of copper, and preferably the copper strip is coated with tin. The metal strip is then formed into a cylinder for insertion to the crimp cylinder. A method for connecting a crimp terminal to an electric wire is also disclosed. The method requires cutting a metal strip to form a plurality of parallel compliant members (e.g., fingers) connected to a base, rolling the cut strip to form a cylindrical insert, positioning the insert within a crimp cylinder of an electric connector with the fingers extending toward the mating end, inserting an electric wire within the cylindrical insert, and crimping the crimp cylinder to secure the electric wire within the cylindrical insert and crimp cylinder.