Wire Termination Clip and Cam Barrel Without Crimp Tools
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Solution Overview
Problem
Existing wire termination methods using crimp tools and die sets are expensive and require periodic calibration, leading to unreliable electrical connections, especially in environments where precise tolerances are critical for safety and operational reasons.
Innovation Solution
A wire termination system comprising a contact with a barrel, clip, and cam portion, where the clip has inwardly directed tines that bias outward upon wire insertion, allowing the clip to be drawn onto the cam portion when the wire is pulled, forming a mechanical and electrical connection without the need for external tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimp tools and die sets are used to terminate wires to contacts, then mechanical and electrical connections can be formed, but the equipment is expensive and requires periodic calibration, leading to unreliable terminations when tolerances are exceeded
Solution Approach 1:
The contact barrel performs the crimping function itself through its integrated cam portion and clip mechanism, eliminating the need for external crimping tools. The cam portion's tapered geometry automatically compresses the clip onto the conductor when the clip is drawn onto the cam, creating a self-contained wire termination system that does not require periodic calibration or expensive equipment
Solution Approach 2:
The patent combines the contact barrel, clip retention mechanism, and crimping function into a single integrated contact assembly. The cam portion is formed as part of the contact barrel, and the clip serves dual purposes of retention and compression, merging multiple functions into one compact structure that eliminates separate crimping tools
2Manufacturing precision
If crimp tools are used with small tolerances for safety, then connection precision is improved, but wire bundles are frequently rejected due to out-of-tolerance terminations
Solution Approach 1:
The cam portion is designed with a specific tapered geometry that controls the compression force applied to the clip. By optimizing the cam angle and dimensions, the system achieves consistent compression within acceptable tolerances without requiring periodic calibration, ensuring high acceptance rates while maintaining precision
Solution Approach 2:
The elastic clip is designed with inherent compliance that absorbs variations in insertion force and conductor dimensions. This cushioning effect compensates for minor dimensional variations, ensuring that terminations remain within tolerance specifications and reducing rejection rates
3Reliability
If a clip with inwardly directed tines is used that biases outward upon wire insertion, then the clip can be drawn onto the cam portion to form a connection, but the structure becomes more complex than simple crimping
Solution Approach 1:
The clip is positioned inside the contact barrel's clip portion, and the cam portion is integrated into the barrel structure. This nested arrangement allows the complex multi-component system to be compactly housed within the contact assembly, minimizing external complexity while maintaining the reliable three-component termination structure
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 provides a simple, safe, and reliable method for wire termination, eliminating the need for expensive crimping tools and ensuring consistent connections by using a clip and cam mechanism to engage the wire, thereby reducing the risk of out-of-tolerance terminations.
Implementation Method 1
The plurality of inwardly directed tines are biased outwards in response to passage of a conductor of the wire through the clip
Implementation Method 2
pulling the wire causes ends of the tines to engage the conductor and draw the clip onto a cam portion of the barrel to reduce a gap of a split ring body of the clip and form an electrical connection
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3B
AI summary
An electrical contact system includes a contact having a barrel with a wire entry portion having a first diameter, a clip portion having a second diameter, and a cam portion having the second diameter at a first end that tapers to a third diameter at a second end near the wire entry portion. The system also includes a clip positioned in the clip portion of the barrel, wherein ends of inwardly directed tines of the clip are configured to engage the conductor to enable the clip to be drawn onto the cam portion in response to a user pulling the wire after insertion of the conductor through the clip.