Partial Wire Reinforcement at Terminal Crimping to Prevent Buckling
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Solution Overview
Problem
The increasing smaller diameter of wires makes them more prone to buckling during insertion into terminal mounting holes, affecting the assemblability of wires with terminals.
Innovation Solution
A wire with terminal that includes a reinforcing material applied to the outer peripheral surface of the insulation coating in a partial circumferential direction, which is strategically positioned to prevent buckling and reduce material usage and weight increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If wire diameter is reduced to achieve smaller connectors and better space utilization, then space efficiency is improved, but wire buckling during assembly increases
Solution Approach 1:
The patent applies reinforcing material only to specific locations on the wire (at the crimping point and extending a predetermined distance therefrom) rather than uniformly along the entire wire length. This local reinforcement provides buckling resistance exactly where needed during assembly while maintaining the overall reduced wire diameter for space efficiency.
Solution Approach 2:
The patent combines the base wire material with a reinforcing material having different physical properties (higher rigidity and/or different thermal expansion coefficient) to create a composite structure. This composite construction provides enhanced mechanical strength and buckling resistance at the reinforcement locations while preserving the lightweight, small-diameter characteristics of the original wire.
2Stability of the object's composition
If reinforcing material is applied to the entire wire circumference to prevent buckling, then buckling resistance is improved, but material usage and weight increase
Solution Approach 1:
The reinforcing material is applied only to the crimping point region (where buckling is most likely to occur during assembly) and extends a predetermined distance from this point, rather than covering the entire wire circumference. This localized application provides sufficient buckling resistance while significantly reducing the quantity of reinforcing material required.
Solution Approach 2:
The patent applies reinforcing material partially (only to the crimping point and a predetermined distance therefrom) rather than completely (entire wire length). This partial action is sufficient to prevent buckling at the critical location without the excessive material usage that would result from full-circumference application.
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 effectively suppresses wire buckling during assembly, maintaining production efficiency and reducing the wire's diameter and weight, while ensuring proper insertion into terminal mounting holes.
Implementation Method 1
a reinforcing material adhered to an outer peripheral surface of the insulation coating
Data Source
AI summary
The present disclosure provides a wire with terminal that can suppress buckling of a wire during assembly. A wire with terminal includes a wire having a core wire made of a conductor and an insulation coating covering the outer periphery of the core wire, and a terminal connected to a lengthwise end portion of the wire. Also, the wire with terminal includes a reinforcing material adhered to an outer peripheral surface of the insulation coating and an unreinforced part where the reinforcing material is not provided, in the circumferential direction of the wire.