Wire Terminal Shell With Resilient Pressurizing for Crimpless Connection
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Solution Overview
Problem
The existing methods for connecting a terminal to a wire require large-scale facilities and jigs for crimping, leading to increased manufacturing costs.
Innovation Solution
A terminal design featuring a terminal body with a wire connecting portion and a shell that includes a resilient pressurizing portion to sandwich the wire, eliminating the need for crimping and allowing for electrical connection without a crimping operation, using a slide portion that can be slidably fitted to the terminal body to apply proper contact pressure based on wire diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crimping facility with dies or jig is used to connect terminal to wire, then reliable electrical connection is achieved, but manufacturing cost increases due to facility investment
Solution Approach 1:
The terminal body itself serves as the crimping tool by incorporating a crimping portion with resilient pressurizing capability. The terminal body directly crimps the wire without requiring external dies or jigs, making the object serve its own connection function and eliminating the need for separate crimping facilities.
Solution Approach 2:
The crimping function is merged with the terminal body structure. The terminal body integrates both the electrical connection function and the crimping mechanism in a single component, combining what were previously separate functions (terminal + crimping tool) into one unified structure.
2Strength
If a crimping facility with dies or jig is used to connect terminal to wire, then secure mechanical connection is achieved, but device complexity increases due to additional equipment
Solution Approach 1:
The terminal body performs the crimping operation itself through its integrated crimping portion, eliminating the need for external crimping facilities. The terminal serves as both the electrical connector and the mechanical crimping tool, simplifying the overall system.
Solution Approach 2:
The crimping function is extracted from external facilities and incorporated directly into the terminal body structure. By taking the crimping capability out of separate equipment and embedding it in the terminal, the system becomes simpler while maintaining connection strength.
3Adaptability or versatility
If resilient pressurizing portion is added to terminal body, then adaptability to different wire diameters is improved, but terminal body complexity increases
Solution Approach 1:
The resilient pressurizing portion allows the crimping force and contact pressure to change dynamically based on wire diameter. By incorporating elastic elements, the terminal automatically adjusts its mechanical parameters (pressure, deformation) to accommodate different wire sizes without requiring manual adjustment or multiple terminal designs.
Solution Approach 2:
The terminal body incorporates dynamic, resilient elements that allow adaptive deformation and pressure adjustment. The crimping portion can dynamically adjust its pressing force based on the wire diameter, transitioning from a static rigid structure to a dynamic adaptive system.
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 solution reduces manufacturing costs by eliminating the need for large-scale crimping jigs and ensures reliable electrical connection for wires of different diameters with proper contact pressure through resilient deformation of the pressurizing portion.
Implementation Method 1
the shell includes a resilient pressurizing portion for resiliently pressurizing the sandwiching portion toward the wire
Data Source
AI summary
A terminal 12 to be connected to a front end part of a wire 11 in an extending direction is provided with a terminal body 15 including a wire connecting portion 20 to be connected to the wire 11, and a shell to be externally fit to the wire connecting portion 20. The wire connecting portion 20 includes a sandwiching portion 18A, 18B extending in the extending direction of the wire 11 and configured to sandwich the wire 11. The shell includes a resilient pressurizing portion for resiliently pressurizing the sandwiching portion 18A, 18B toward the wire 11.