Universal Crimp Terminal for Multi-Size Wire Sealing
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Solution Overview
Problem
The existing methods for connecting electrical wires of varying sizes in vehicles are cumbersome due to the need for multiple types of crimp terminals and complex crimping processes, which increase manufacturing complexity and the risk of water infiltration and corrosion.
Innovation Solution
A method of manufacturing an electrical wire connecting structure using a terminal with a tube-shaped portion and a conductor portion, where the terminal is crimp-connected to the electrical wire, with specific inner diameters and cross-sectional areas to secure a strong holding force and reduce the number of terminal types, using a stepped tube design and laser welding for sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different types of crimp terminals are prepared for electrical wires of different sizes, then the adaptability to various wire sizes is improved, but the device complexity and manufacturing process become cumbersome
Solution Approach 1:
The patent applies universality by designing a single crimp terminal structure that can accommodate multiple wire sizes through adjustable crimping positions. The terminal body is designed with a universal crimping chamber that can adapt to different conductor diameters, eliminating the need for multiple specialized terminals while maintaining compatibility across various wire gauges.
Solution Approach 2:
The patent utilizes parameter changes by allowing the crimping force, crimping position, and terminal geometry to be adjusted based on the wire size being connected. This enables a single terminal design to optimize its performance parameters for different wire diameters, achieving versatility without increasing the number of terminal types.
2Adaptability or versatility
If multiple crimp terminal types are used for different wire sizes, then the adaptability is improved, but the manufacturing process complexity increases
Solution Approach 1:
The terminal design incorporates a universal crimping mechanism that can handle multiple wire sizes through a single manufacturing process. The terminal body is produced as a unified component with standardized features that accommodate various conductor dimensions, simplifying the manufacturing workflow while maintaining broad applicability.
Solution Approach 2:
The patent applies segmentation by dividing the crimping function into distinct zones within the terminal body, allowing different sections to accommodate different wire sizes. This internal segmentation enables a single terminal type to perform multiple sizing functions without requiring multiple terminal variants.
3Ease of manufacture
If conventional crimp terminals are used without sealing, then the manufacturing process is simple, but water infiltration and corrosion risk increase
Solution Approach 1:
The patent implements a sealing mechanism using flexible sealing elements that conform to the crimped wire and terminal interface. This sealing layer prevents water infiltration while being integrated into the terminal structure in a way that does not significantly complicate the manufacturing process, maintaining ease of production while enhancing reliability.
Solution Approach 2:
The sealing structure is designed to prevent water infiltration proactively by creating a barrier before water can reach the electrical connection. The sealing elements are pre-positioned within the terminal body to automatically engage and seal the connection interface, providing preliminary protection against corrosion and water damage.
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 approach simplifies the manufacturing process, reduces the number of terminal types required, enhances electrical wire holding force, and prevents water infiltration, thereby improving the reliability and longevity of electrical connections.
Implementation Method 1
compressing the tube-shaped portion and the conductor portion of the covered electrical wire to crimp-connect the tube-shaped portion and the conductor portion
Implementation Method 2
laser welding for sealing
Data Source
AI summary
A method of manufacturing an electrical wire connecting structure in which a terminal having a tube-shaped portion and a conductor portion of a covered electrical wire are crimped at the tube-shaped portion, and the tube-shaped portion has a conductor crimping portion corresponding to the conductor portion, and a cover crimping portion corresponding to a cover portion of the covered electrical wire, the method comprising the steps of a) forming the tube-shaped portion, b) inserting the covered electrical wire into a corresponding space, c) crimping a welded portion of the conductor, and d) compressing the cover crimping portion.