Wave-Formed Crimp Connector Wire Retention
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Solution Overview
Problem
Existing crimp connectors with smooth surfaces fail to securely hold tension-stressed wires, such as those made of shape memory alloys, due to the risk of slippage, and pre-assembled connectors with recesses are costly and complex to manufacture.
Innovation Solution
A crimp connector design featuring flat clamping surfaces that are deformed to create a wave-like shape using a tool with clamping jaws, securely holding the wire in place without projections or recesses, thereby enhancing the mechanical stability and ease of production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If smooth clamping surfaces are used in the crimp connector, then manufacturing is simple and cost-effective, but the wire can slip out and mechanical connection reliability deteriorates
Solution Approach 1:
The clamping plates are pre-formed with flat surfaces for easy manufacturing, then deformed in advance during the crimping process to create the wave pattern that secures the wire. This preliminary deformation approach maintains manufacturing simplicity while achieving reliable wire retention.
Solution Approach 2:
The flat clamping surfaces are transformed into a wave-like curved pattern through deformation. This curvature creates multiple contact points and mechanical interlocking with the wire, preventing slippage while maintaining the simplicity of the original flat plate structure.
2Reliability
If projections and recesses are pre-assembled in the clamping plates, then wire retention reliability improves, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of pre-assembling projections and recesses, the clamping plates are kept simple and flat during manufacturing. The wave pattern is created in advance during the crimping operation itself, eliminating the need for complex pre-formed features while achieving the same wire retention effect.
Solution Approach 2:
The surface geometry parameter of the clamping plates is changed from flat to wave pattern through deformation. This parameter change creates the necessary mechanical interlocking features without requiring additional components or complex manufacturing processes.
3Strength
If projections are added to clamping plates to press wire into recesses, then mechanical connection strength improves, but manufacturing precision requirements and production cost increase
Solution Approach 1:
The wave pattern is created during the crimping process itself rather than requiring pre-assembled projections and recesses. This eliminates the need for high-precision alignment of complementary features while achieving strong mechanical connection through the deformed wave structure.
Solution Approach 2:
The functions of creating retention features and applying clamping force are merged into a single deformation operation. The wave pattern is formed simultaneously with the crimping action, eliminating the need for separate precision-machined features and reducing manufacturing complexity.
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 cost-effective and reliable mechanical and electrical connection for wires, including those made of shape memory alloys, by creating a wave-like deformation in the clamping plates that securely guides the wire, addressing the issues of slippage and manufacturing complexity.
Implementation Method 1
The inner surfaces of the first and second clamping plate, at least facing one another in the assembled state, are executed in a first form in the preassembled state... the first and second clamping plate are deformed with a tool in the assembled state in such a way to a second form differing from the first that the wire forms at least a wave through the deformation of the first and second clamping plates
Implementation Method 2
the first and second clamping plate are deformed with a tool in the assembled state in such a way to a second form differing from the first that the wire forms at least a wave through the deformation of the first and second clamping plates
Data Source
AI summary
A connection arrangement has a crimp connector and a wire fixed in place in it, the crimp connector having a first and a second clamping plate, both single pieces, which in an assembled state clamp the wire between them and fix the wire in place with a tensile strength force acting in a longitudinally axial direction. Inner surfaces of the first and second clamping plate face one another at least in the assembled state are executed in a first form in the preassembled state. The first and second clamping plate fit tightly with one another and are deformed in the assembled state with a tool into a second form differing from the first that the wire, due to the deformation of the first and second clamping plates, forms at least one wave. A related valve and a related method are also disclosed.