Terminal-Attached Wire Crimp Protrusion for Lower Voltage Drop
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Solution Overview
Problem
Existing terminal-attached electric wires face challenges in improving electrical performance due to limitations in changing the shape of the terminals and swaging dies, as seen in conventional technologies like JP2022-37547 A.
Innovation Solution
The terminal-attached electric wire design includes a conductor crimping portion with a protrusion extending towards the electric-wire covering material, allowing efficient contact pressure transmission without significantly altering the terminal's shape by forming protrusions during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shape of terminals or swaging die is changed to improve electrical performance, then electrical performance is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The terminal is divided into distinct functional portions: a conductor crimping portion for electrical contact and a protrusion that extends toward the electric-wire covering material. This segmentation allows each portion to be optimized independently for its specific function while maintaining overall manufacturing feasibility
Solution Approach 2:
The protrusion is added locally to the conductor crimping portion to specifically address electrical performance in the contact region, while the rest of the terminal maintains its conventional simple shape. This localized modification improves electrical performance without requiring complex changes to the entire terminal structure
2Reliability
If the terminal shape is significantly altered to improve contact pressure, then electrical performance is improved, but ease of manufacture deteriorates
Solution Approach 1:
The protrusion is formed as an integral part of the conductor crimping portion during the terminal manufacturing process, before the actual crimping operation. This preliminary formation of the protrusion structure allows it to pre-position and guide the conductor into optimal alignment, ensuring improved contact pressure without requiring complex post-manufacturing adjustments
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 design enhances electrical performance by minimizing shape changes to the terminals, improving contact pressure and reducing voltage drop, thus optimizing electrical conductivity.
Implementation Method 1
a protrusion in contact with the conductor and extending from the conductor crimping portion toward the electric-wire covering material
Data Source
AI summary
A terminal-attached electric wire includes: an electric wire having a conductor and an electric-wire covering material for covering the conductor; and a terminal connected to the conductor of the electric wire. The terminal includes: a conductor crimping portion in contact with the conductor; and a protrusion in contact with the conductor and extending from the conductor crimping portion toward the electric-wire covering material.