Asymmetric Wire Barrel Crimp for Wire Center Alignment
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Solution Overview
Problem
Existing wire terminals cause significant deviation in the center of the wire, affecting current flow due to uneven thickness on both sides, leading to adverse effects on the crimped connection.
Innovation Solution
The wire terminal design includes a wire barrel with one-side and other-side pieces that overlap radially, shifting the center towards the thicker side, and an insulation barrel with locked pieces to maintain high holding force and prevent deviation, ensuring even coverage and reduced displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If both extending portions are doubly arranged on one side in the width direction of the terminal, then the wire barrel can provide sufficient holding force, but the thickness becomes larger on that side causing the wire center to deviate in the width direction
Solution Approach 1:
The wire barrel is designed with asymmetric thickness distribution: one side has a single extending portion while the other side has doubly arranged extending portions. This asymmetric configuration compensates for the natural deviation of the wire center by making the wire barrel thicker on the side where the wire center tends to shift, thereby maintaining proper alignment without requiring symmetric doubling on both sides
2Manufacturing precision
If the wire barrel center is shifted toward the other side with respect to the wire center held by the insulation barrel, then wire deviation is suppressed, but the structure becomes more complex
Solution Approach 1:
The wire barrel employs an asymmetric structure where the center is deliberately shifted toward the other side relative to the insulation barrel center. This is achieved through asymmetric arrangement of extending portions (single on one side, double on the other) rather than through complex adjustment mechanisms, thereby suppressing wire deviation while maintaining relatively simple manufacturing processes
Data Source
AI summary
A wire with terminal includes a wire and a terminal. The wire includes a conductor and a coating. The wire includes a conductor exposed portion in which an outer peripheral surface of the conductor is exposed. The terminal includes an insulation barrel for holding the coating, and a wire barrel to be connected to the conductor exposed portion in front of the insulation barrel. The wire barrel includes a wire barrel base portion, a one-side wire barrel piece extending from an end part of the wire barrel base portion on one side in a width direction toward the other side to cover an outer periphery of the conductor exposed portion and an other-side wire barrel piece extending from an end part of the wire barrel base portion on the other side to be laid on an outer periphery of the one-side wire barrel piece on the other side.